Smoking Substitute Consumable

ABSTRACT

The present disclosure relates to an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a filter element wherein the filter element is at least partly circumscribed by a flavored sleeve.

CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE STATEMENT

This application is a non-provisional application claiming benefit to the international application no. PCT/EP2019/079135 filed on Oct. 25, 2019, which claims priority to GB 1817571.1 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079139 filed on Oct. 25, 2019, which claims priority to GB 1817572.9 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079142 filed on Oct. 25, 2019, which claims priority to GB 1817551.3 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079145 filed on Oct. 25, 2019, which claims priority to GB 1817575.2 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079148 filed on Oct. 25, 2019, which claims priority to GB 1817539.8 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079154 filed on Oct. 25, 2019, which claims priority to GB 1817576.0 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079164 filed on Oct. 25, 2019, which claims priority to GB 1817538.0 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079166 filed on Oct. 25, 2019, which claims priority to GB 1817577.8 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079169 filed on Oct. 25, 2019, which claims priority to GB 1817540.6 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079175 filed on Oct. 25, 2019, which claims priority to GB 1817543.0 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079180 filed on Oct. 25, 2019, which claims priority to GB 1817557.0 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079184 filed on Oct. 25, 2019, which claims priority to GB 1817556.2 filed on Oct. 29, 2018. This application also claims benefit to the international application no. PCT/EP2019/079201 filed on Oct. 25, 2019, which claims priority to GB 1817570.3 filed on Oct. 29, 2018.

FIELD OF THE DISCLOSURE

The present disclosure relates to a consumable for use in a smoking substitute system and particularly, although not exclusively, to a heat-not-burn (HNB) consumable.

BACKGROUND

During the manufacturing process for tobacco products, such as cigarettes, tobacco waste is produced. The tobacco waste is typically in the form of tobacco dust, leaf or stem. The tobacco waste can be collected and processed to provide what is known as reconstituted tobacco, or “recon”.

Two distinct methods are most commonly employed to manufacture reconstituted tobacco, these are (1) a paper-making process (i.e., to provide “Paper Recon”), and (2) slurry casting (to provide “Slurry-type Recon”). The products that result from these distinct processes have notably different properties and characteristics. For example, slurry-type recon generally has improved aroma/flavor and nicotine content in comparison to paper recon, yet slurry-type recon is typically more easily broken and often has poorer uniformity of quality.

In slurry casting the tobacco waste is milled to a fine powder and mixed with an aqueous solvent, typically water, and combined with a binding agent. The resultant slurry may undergo further milling to reduce the particle size of the tobacco material further. The slurry is then cast on a surface and dried to form a sheet. The dried sheet may be shredded to be used within various tobacco products, for example as a cigarette filler.

In the paper-making process the tobacco waste is mechanically beaten in the presence of an aqueous solvent to digest and process the tobacco into workable fibers. Subsequently, water soluble compounds present in the tobacco are extracted into the aqueous solvent. The aqueous extract and insoluble fibrous portion are separated. The separated fibrous portion, which may also be described as a “pulp”, undergoes further processing to form a base sheet via a typical paper-making procedure. The aqueous extract is concentrated and then reapplied to the base sheet. The base sheet is then dried to form a paper.

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances are generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Conventional combustible smoking articles, such as cigarettes, typically comprise a cylindrical rod of tobacco comprising shreds of tobacco which is surrounded by a wrapper, and usually also a cylindrical filter axially aligned in an abutting relationship with the wrapped tobacco rod. The filter typically comprises a filtration material which is circumscribed by a plug wrap. The wrapped tobacco rod and the filter are joined together by a wrapped band of tipping paper that circumscribes the entire length of the filter and an adjacent portion of the wrapped tobacco rod. A conventional cigarette of this type is used by lighting the end opposite to the filter, and burning the tobacco rod. The smoker receives mainstream smoke into their mouth by drawing on the mouth end or filter end of the cigarette.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute systems (or “substitute smoking systems”) in order to avoid the smoking of tobacco.

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute systems include electronic systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a “vapor”) that is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavorings without, or with fewer of, the odor and health risks associated with traditional smoking.

In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and with combustible tobacco products. Some smoking substitute systems use smoking substitute articles that are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end.

The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories.

There are a number of different categories of smoking substitute systems, each utilizing a different smoking substitute approach.

One approach for a smoking substitute system is the so-called “heat not burn” (“HNB”) approach in which tobacco (rather than an “e-liquid”) is heated or warmed to release vapor. The tobacco may be leaf tobacco or reconstituted tobacco. The vapor may contain nicotine and/or flavorings. In the HNB approach the intention is that the tobacco is heated but not burned, i.e., the tobacco does not undergo combustion.

A typical HNB smoking substitute system may include a device and a consumable. The consumable may include the tobacco material. The device and consumable may be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by a heating element of the device, wherein airflow through the tobacco material causes moisture in the tobacco material to be released as vapor. A vapor may also be formed from a carrier in the tobacco material (this carrier may for example include propylene glycol and/or vegetable glycerin) and additionally volatile compounds released from the tobacco. The released vapor may be entrained in the airflow drawn through the tobacco.

As the vapor passes through the consumable (entrained in the airflow) from an inlet to a mouthpiece (outlet), the vapor cools and condenses to form an aerosol for inhalation by the user. The aerosol will normally contain the volatile compounds.

In HNB smoking substitute systems, heating as opposed to burning the tobacco material is believed to cause fewer, or smaller quantities, of the more harmful compounds ordinarily produced during smoking. Consequently, the HNB approach may reduce the odor and/or health risks that can arise through the burning, combustion and pyrolytic degradation of tobacco.

In some cases, the aerosol passing from the mouthpiece (i.e., being inhaled by a user) may not be in a desirable state. Thus, it may be desirable to alter one or more characteristics of the aerosol before it is inhaled by the user.

HNB consumable are typically provided in a cardboard packaging/box which may optionally have a metallized paper liner.

There is a need for an improved design of HNB consumables to enhance the user experience and improve the function of the HNB smoking substitute system.

Furthermore, there is a need for an improved packaging for smoking substitute articles (e.g., HNB consumables) which provides advantages for the user of the articles/consumables.

The present disclosure has been devised in the light of the above considerations.

SUMMARY OF THE DISCLOSURE

First Mode: A Consumable Providing at Least One Flavored Sleeve Downstream of an Aerosol Forming Substrate

At its most general, a first mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable comprising at least one flavored sleeve downstream of an aerosol-forming substrate.

According to a first aspect of the first mode, the present invention provides an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a filter element wherein the filter element is at least partly circumscribed by a flavored sleeve.

By providing an aerosol-forming article having a filter element at least partly circumscribed by a flavored sleeve (i.e., a sleeve carrying a flavorant additive), the filter element can be permeated with the flavor additive e.g., during storage and transport such that, upon use of the article, the flavorant is entrained within vapor/aerosol passing through the filter element. In this way, the user is provided with a flavored vapor/aerosol which can enhance the user's experience.

Optional features will now be set out. These are applicable singly or in any combination with any aspect. In some embodiments, the aerosol-forming article is a heat not burn (HNB) consumable.

The filter element is downstream of the aerosol-forming substrate. The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

In some embodiments, the flavored sleeve is a tubular sleeve that encircles the filter element. It may have an axial length that is substantially the same as the filter element. It may have a greater axial length than the filter element. At least a portion of the flavored sleeve may be formed of an absorbent material e.g., paper or cardboard and may be impregnated with flavorant. Alternatively, and/or additionally, the sleeve may be coated with flavorant on its inside surface (which will be in contact with the filter element). The sleeve may be formed of a non-absorbent material such a plastics material or a metallic foil coated with flavorant.

Herein, the term “flavorant” encompasses any natural or artificial substance or composition which imparts a pleasant or desirable flavor to the aerosol.

The flavorant may comprise a natural extract from a plant source (e.g., fruit extract).

The flavorant may comprise a derivative of a natural extract, for example a purified form thereof.

In some embodiments, the flavorant is added to the article in purified or substantially purified form.

In some embodiments, the flavorant comprises a flavored compound or mixture of compounds. In some embodiments, the flavorant comprises a compound which does not occur naturally in tobacco, for example menthol or other organic aromatic compound. It may include menthol, liquorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavorants.

In some embodiments, the filter element further comprises at least one flavor pod to further enhance the flavor of the vapor/aerosol for inhalation by the user.

The flavor pod may be a capsule or micro-moulding. The flavor pod may have an outer shell which may be solid/rigid. The outer shell may be crushable or meltable to release the flavor from the flavor pod.

The flavor pod may be substantially spherical. flavor pods typically known as “crush balls” can be used.

The flavor pod may carry a liquid flavorant. It may include menthol, liquorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. It may be the same or different to the flavorant carried by the flavored sleeve.

The flavor pod may be provided at the axial center of the filter element flavor pod. In other embodiments, the flavor pod is provided is provided at or proximal an axial end of the filter element e.g., at or proximal the upstream axial end of the filter element.

In some embodiments, the filter element is a terminal filter element provided at the downstream axial end of the aerosol-forming article. The terminal filter element may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In other embodiments, the filter element is an upstream filter element provided upstream from the downstream axial end of the article. The upstream element may be circumscribed by the (paper) wrapping layer.

The flavored sleeve may be overlaid by the wrapping layer or tipping paper and therefore can be used to contain the contents of the flavor pod after rupture within the filer element and avoid unsightly staining of the wrapping layer/tipping paper.

In some embodiments, the upstream filter element is provided axially adjacent the aerosol-forming substrate. In these embodiments, the flavor pod may be provided at the axial center of the upstream filter element (so that rupture of the flavor pod results in wicking of the flavor into the filter element) or at the upstream axial end of the upstream filter element in abutment with the downstream axial end of the aerosol-forming substrate (so that rupture of the flavor pod results in some wicking of the flavor into the aerosol-forming substrate).

In some embodiments, the article comprises a terminal filter element and an upstream filter element which may be axially adjacent or axially spaced form one another. In these embodiments, the flavored sleeve may at least partly (e.g., fully) circumscribe one or both of the filter elements. Alternatively, there may be two flavored sleeves, each circumscribing a respective filter element. One or both of the upstream and terminal filter elements may comprise a flavor pod.

The or at least one of the filter element(s) may be a hollow bore filter element (with a hollow, axial bore) or a solid filter element (with no axial bore). Where the filter element(s) comprise(s) a flavor pod, the filter element is preferably a solid filter element.

The or at least one of the filter element(s) (e.g., the terminal and or upstream filter element) may be comprised of cellulose acetate or polypropylene tow.

The or at least one of the filter element(s) (e.g., the terminal and or upstream filter element) may be comprised of activated charcoal.

The or at least one of the filter element(s) (e.g., the terminal and or upstream filter element) may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal and or upstream filter element) may be comprised of plant material (e.g., extruded tobacco). The or each filter element may be at least partly (e.g., entirely) circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer).

The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm e.g., between 10 and 12 mm.

Where the filter element(s) is/are a hollow bore filter element, the or each hollow bore may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opoids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos. Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco, and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenised (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %. Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins. Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof. Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, liquorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed/dosed throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm. The cavity may have an axial length of around 3 to 7 mm, e.g., 3, 3.5 or 4 mm.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. It may be provided between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer element may comprise a tubular element e.g., a cardboard tube. The spacer element may be circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm e.g., between 12 and 14 mm or 13 and 14 mm e.g., around 14 mm.

In a second aspect of the first mode, there is provided a system comprising an article/consumable according to the first aspect of the first mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable.

The device (e.g., the main body) may further comprise an electrical power supply e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the first mode, there is provided a method of using a system according to the second aspect of the first mode, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The method preferably further comprises rupturing the flavor pod during heating of the article/consumable to release a flavor additive.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the first mode may be applied to any other aspect of the first mode. Furthermore, except where mutually exclusive, any feature or parameter of the first mode described herein may be applied to any aspect and/or combined with any other feature or parameter of the first mode described herein.

Second Mode: HNB Consumable Providing an Unimpeded Flow Passage Around a Filter Element

At its most general, a second mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable that provides an unimpeded flow passage around a filter element.

According to a first aspect of the second mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and at least one filter element downstream of the substrate wherein the article has at least one unimpeded flow path along the outer surface of the filter element and wherein the filter element comprises a flavorant additive.

By providing a filter element downstream of the aerosol-forming substrate, the filter element having at least one unimpeded flow path along its outer surface, it is possible to provide a flow path for vapor/aerosol from the aerosol-forming substrate to the downstream axial end (mouth-end) of the consumable such that the volume of visible vapor (total particulate matter TPM) is maintained at a level desirable to the user. The flavorant additive within the filter element imparts flavor to the portion of the vapor/aerosol passing through the filter rather than along its outer surface thus providing a good balance of visible vapor and flavored vapor.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the second mode.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The filter element may have an outer surface comprising at least one longitudinally-extending channel.

The filter element may have an outer surface comprising a plurality of flow paths along the outer surface of the filter element e.g., provided by a plurality of longitudinally-extending channels. For example, the entire of the outer surface may be convoluted/corrugated with a series of longitudinally-extending parallel channels and ridges.

The filter element may be a solid filter element (i.e., having no hollow axial bore).

The filter element may be a terminal filter element provided at the downstream axial end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

The article/consumable may further comprise an upstream filter element upstream from the terminal filter element. The upstream filer element may be a solid or hollow bore filter element.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/upstream filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of paper. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of extruded plant material. The or each filter element may be circumscribed at its outer surface with a plug wrap e.g., a paper plug wrap. The plug wrap will conform to the longitudinally-extending channels on the outer surface of the filter element where provided. This the plug warp may be corrugated.

The article/consumable may further comprise a sleeve (e.g., a paper or cardboard sleeve) at least partially (e.g., fully) circumscribing the filter element having at least one (e.g., a plurality of) longitudinally-extending channel(s). The sleeve overlays the peaks in the corrugated outer surface of the filter element and leaves the longitudinally-extending channels unimpeded.

The flavorant may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate. The flavorant may be provided as a flavor thread, i.e., the filter element may comprise a thread (e.g., a cotton thread) soaked in flavorant. The flavor thread may be longitudinally-extending e.g., it may extend the length of the filter element e.g., along the central axis of the filter element.

The combination of a flavor thread and a filter element having a corrugated outer surface allows the vapor to be flavored without deforming the outer surface of the filter element. Known flavored filters often comprise crush-balls having a frangible shell that is ruptured by crushing. Such crushing would deform the corrugated outer surface of the filter element leading to blocking of the flow passages/longitudinally-extending channels.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm e.g., between 10 and 12 mm.

Where the upstream filter element is a hollow bore filter element, the filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal and upstream filter elements may be adjacent one another or may be spaced apart. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element (and its sleeve where present) plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the upstream and terminal filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the upstream and terminal filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a tubular element e.g., a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm e.g., around 7 mm. It may have an axial length of between 10 and 15 mm e.g., between 12 and 14 mm or 13 and 14 mm e.g., around 14 mm.

In a second aspect of the second mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the second mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the second mode, there is provided a method of using a smoking substitute system according to the second aspect of the second mode, the method comprising:

-   -   a. inserting the article/consumable into the device; and     -   b. heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the second mode may be applied to any other aspect of the second mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the second mode and/or combined with any other feature or parameter described herein.

Third Mode: A Consumable Providing a Spacer Element Adapted to Impart Flavor to the Vapor/Aerosol

At its most general, a third mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable, comprising a spacer element adapted to impart flavor to the vapor/aerosol.

According to a first aspect of the third mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and a spacer element downstream of the substrate, wherein the spacer element comprises a flavorant.

By providing a spacer element comprising a flavorant, it is possible to impart flavorant to the aerosol/vapor generated by heating of the aerosol-forming substrate thus enhance the user experience.

The flavorant can be added/applied to the spacer element after manufacture of the spacer element meaning that contamination of the article/consumable primary production line will not be contaminated unlike the production line of articles/consumables where a flavorant is incorporated (e.g., into the substrate or into a filter element) during production.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the third mode.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be at least partly circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable. There may be an upstream filter element (upstream of the downstream axial end).

There may be a plurality of e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/upstream filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of paper. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a solid filter element. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a hollow bore filter element. The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements e.g., the terminal filter element may include a capsule e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., any of the flavorants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavorant. The capsule may be located at the axial center of the filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable comprises a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable e.g., between the aerosol-forming substrate and the terminal filter element.

The spacer element may be provided axially adjacent and upstream of the terminal filter element. For example, the spacer element may be provided between the terminal filter element and the upstream filter element.

The spacer element may be a tubular spacer element, for example, it may be a porous tubular element. It may comprise a cardboard tube or a tube formed of extruded plastics material. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

The spacer element comprises a flavorant. For example, the spacer element may be impregnated with flavorant. The spacer element may be spayed or coated on its inner surface such that the flavorant can make intimate contact with the vapor/aerosol within the cavity/chamber within the spacer element. In this way, the aerosol/vapor generated by heating the aerosol-forming substrate exposed to the flavorant so that the user is provided with a flavored vapor/aerosol for inhalation.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed on or in the spacer element or may be provided in isolated locations and/or varying concentrations throughout the spacer.

In a second aspect of the third mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the third mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the third mode, there is provided a method of using a smoking substitute system according to the second aspect of the third mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the third mode may be applied to any other aspect of the third mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the third mode and/or combined with any other feature or parameter described herein.

Fourth Mode: A Consumable Providing an Aerosol-Forming Substrate at the Upstream End of the Consumable

At its most general, a fourth mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable having an increased level of flavorant.

According to a first aspect of the fourth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and at least one of a downstream filter element, spacer element and aerosol-cooling element, wherein the article is circumscribed by a flavored outer wrapper and wherein at least one of the substrate, the filter element, the spacer element, and the cooling element comprises a flavorant additive.

By providing an article having both a flavored outer wrapper and a flavorant additive within one or more of the substrate, the filter element, the spacer element and the cooling element, the user is provided with a vapor/aerosol having an enhanced flavor.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the fourth mode. The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The outer wrapper may comprise a wrapping layer (e.g., a paper wrapping layer) at least partly (e.g., fully) circumscribing the aerosol-forming substrate. The wrapping layer may further fully or partly circumscribe one or more of the filter element, aerosol-cooling element and spacer element.

In some embodiments, the outer wrapper may further comprise a tipping layer (e.g., a tipping paper layer) at its axial downstream end which overlies a portion of the wrapping layer.

For example, in some embodiments, the article/consumable comprises a terminal filter element at the downstream axial end which may be joined to the upstream elements forming the article/consumable by the tipping (paper) layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the article/consumable comprises an upstream filter element (upstream of the downstream axial end of the article/consumable (e.g., upstream of the terminal filter element)). The upstream filter element (which may be axially adjacent and downstream of the substrate) may be at least partly circumscribed by the wrapping layer.

In some embodiments, at least a portion of the wrapping layer and/or tipping paper may be flavored.

In some embodiments, at least a portion of the tipping paper may be flavored on its outer surface. The tipping paper may be flavored on its outer surface at a portion closest to the downstream axial end of the article/consumable. The entire axial length of the tipping paper may be flavored on its outer surface.

In this way, as the user inhales on the article/consumable with the axial upstream end in their mouth, flavorant additive from the outer surface of tipping paper enters their mouth.

In some embodiments, at least a portion of the wrapping layer may be flavored on its inner surface. The wrapping layer may be flavored on its inner surface at a portion overlying one or more of the substrate, the upstream filter element, the cooling element and the spacer element. The entire axial length of the wrapping layer may be flavored on its inner surface.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be coated, painted or sprayed onto the outer wrapper (e.g., the outer surface of the tipping paper and/or the inner surface of the wrapping layer) or the outer wrapper may be impregnated with the flavorant.

The article/consumable further comprises a flavorant additive (e.g., flavorant as described above) within one or more of the substrate, the filter element (e.g., the upstream and/or the terminal filter element), the cooling element, and the spacer element. The flavorant additive may be provided in solid or liquid form. It may be provided in a frangible (e.g., meltable or crushable) capsule within one or more of the substrate, the filter element (e.g., the upstream and/or the terminal filter element), and the cooling element. It may be provided as a flavored thread, e.g., a flavor additive-soaked cotton thread within one or more of the substrate, the filter element (e.g., the upstream and/or the terminal filter element), and the cooling element. It may be provided as a coating on or impregnated within the spacer element.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos. Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenised tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant additive may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant additive may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable. There may be an upstream filter element (upstream of the downstream axial end). The upstream and terminal filter elements may be axially adjacent one another or may be spaced apart.

The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of activated charcoal.

The or at least one of the filter element(s) (e.g., the terminal element and/or upstream filter element) may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal element/upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a solid filter element. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a hollow bore filter element. The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The or at least one of the filter elements (e.g., the terminal filter element and/or the upstream filter element) may include a capsule, e.g., a crushable capsule (crush-ball) or a meltable capsule containing a liquid flavorant additive, e.g., any of the flavorants listed above. The crushable capsule can be crushed by the user during smoking of the article/consumable to release the flavorant additive. The capsule may be located at the axial center of the filter element. The or at least one of the filter elements (e.g., the terminal filter element and/or the upstream filter element) may comprise a flavored thread, i.e., a thread soaked with flavorant additive, e.g., an axially extending flavored thread.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer, e.g., by a flavored portion of the wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material (e.g., coated or sprayed with the flavorant additive) to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be provided between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may be a tubular spacer element e.g., it may comprise a cardboard or plastic material tube. The tube may be coated or spayed on its inners surface with the flavorant additive or the tube may be impregnated with the flavorant additive. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer, e.g., by a flavored portion of the wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the fourth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the fourth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect, of the fourth mode there is provided a method of using a smoking substitute system according to the second aspect of the fourth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the fourth mode may be applied to any other aspect of the fourth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the fourth mode and/or combined with any other feature or parameter described herein.

Fifth Mode: A Consumable Providing a Means to Prevent Ignition of the Article and Provide Flavor

At its most general, a fifth mode of the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable. The invention provides an aerosol-forming article comprising a means to prevent ignition of the article and provide flavor, thereby offering an improved user experience, including improved safety during use.

According to a first aspect of the fifth mode, the present invention provides an aerosol-forming article (e.g., a smoking substitute article such as a heat-not-burn consumable) comprising an aerosol-forming substrate and a layer of non-combustible material comprising a flavorant, wherein the layer of non-combustible material encloses at least a portion of the aerosol-forming substrate.

The layer of non-combustible material in the article acts as a carrier or substrate for the flavorant, releasing the flavorant into the aerosol in response to heating. When heated, the flavorant volatilizes into the main aerosol stream which is inhaled by the user. Furthermore, prior to use (for example, during storage and/or shipping), a portion of the flavorant may diffuse from the non-combustible material into the aerosol-forming substrate, improving the flavor of the aerosol released from the aerosol-forming substrate itself and creating a smoother flavor experience. The layer of non-combustible material also prevents mis-use of the article by preventing ignition of the aerosol-forming substrate.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the fifth mode.

The aerosol-forming article is preferably a smoking substitute article, more preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosolize with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include those selected from the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise at least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material. The aerosol-forming substrate may comprise from 50 to 80 wt % plant material, for example from 50 to 75 wt %, from 55 to 80 wt %, from 55 to 75 wt %, from 50 to 70 wt %, from 55 to 70 wt %, from 60 to 75 wt % or from 60 to 70 wt %.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the solvent is water. In some embodiments, the aerosol forming substrate has a solvent content of between 5 and 10 w t %, e.g., between 6-9 wt % such as between 7-9 wt %.

Herein, the term “flavorant” encompasses any natural or artificial substance or composition which imparts a pleasant or desirable flavor to the aerosol. The flavorant may comprise a natural extract from a plant source (e.g., fruit extract). The flavorant may comprise a derivative of a natural extract, for example a purified form thereof. In some embodiments, the flavorant is added to the article in purified or substantially purified form. In some embodiments, the flavorant comprises a flavored compound or mixture of compounds. In some embodiments, the flavorant comprises a compound which does not occur naturally in tobacco, for example menthol or other organic aromatic compound.

In addition to the non-combustible material comprising flavorant, there may also be flavorant provided at other locations within the article, including but not limited to the aerosol-forming substrate and the filter. The flavorant(s) used elsewhere may be the same or different from the flavorant provided on the non-combustible material layer.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) or tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical rod-shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

In some embodiments, the layer of non-combustible material at least partially (e.g., fully) circumscribes the axially-extending curved surface of the cylindrical rod of plant material. It may have an axial length substantially matching the axial length of the aerosol-forming substrate. The axial, upstream end face of the tobacco rod may not be covered by the layer of non-combustible material. This may allow for inter alia the penetration of a heating element directly into the aerosol-forming substrate without the need to pass through the non-combustible material.

Herein, the term “non-combustible material” pertains to a material which offers increased resistance to ignition and/or combustion relative to standard materials used in smoking articles such as cigarettes. In some embodiments, the term “non-combustible material” pertains to a material which does not burn when exposed to fire. For example, the non-combustible material may comprise or consist of a material which is inherently incombustible under the conditions experienced by a HNB consumable, such as a metal or alloy with a suitably high melting point (e.g., aluminum).

The non-combustible material may alternatively comprise a composite material or a material which comprises an additive which imparts non-combustibility to the material. In some embodiments, the non-combustible material has a relatively high thermal conductivity. In some embodiments, the non-combustible material has a thermal conductivity of at least 100 Wm-1K-1, for example at least 120 Wm-1K-1, for example at least 140 Wm-1K-1, for example at least 150 Wm-1K-1, for example at least 160 Wm-1K-1, for example at least 170 Wm-1K-1, for example at least 200 Wm-1K-1. In some embodiments, the non-combustible material has a relatively high melting point, i.e., a melting point higher than the temperatures to which a HNB consumable is exposed during use. In some embodiments, the non-combustible material has a melting point of at least 300° C., for example at least 350° C., for example at least 400° C., for example at least 450° C., for example at least 500° C., for example at least 550° C., for example at least 600° C.

Herein, the term “metal” or “metallic” encompasses traditional single-element metals but also mixtures of metals, including alloys. The term “foil” has its usual meaning, referring to a thin flexible sheet or layer of material, such as metal.

Herein, the term “laminate” or “laminar structure” refers in the traditional sense to an assembly of two or more thin layer structures such as films, foils, papers or wrappers lying in a laminar arrangement, one on top of the other. Individual layers of the laminate may be loosely associated (i.e., not strongly or permanently attached or bonded to one another), or may be partially or fully adhered to one another. For example, a layer of foil may encompass an aerosol-forming substrate and a layer of paper may be wrapped around the layer of foil to form a laminate structure, and the two layers may or may not be adhered to one another (for example, the layers may be held in place merely by friction between the layers rather than adhesive).

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

In some embodiments, the aerosol-forming article comprises a wrapping layer with a laminate structure comprising a first layer and a second layer, the first layer being an inner layer adjacent the aerosol-forming substrate and the second layer lying radially outside the first layer, wherein the inner layer comprises the non-combustible material and the outer layer comprises a cellulosic material.

In this way, the layer of non-combustible material is located adjacent the aerosol-forming substrate which facilitates the diffusion of flavorant into the aerosol-forming substrate, both prior to use (e.g., during storage) and during use, upon heating. The laminate structure provides an outer layer of cellulosic material for easier handling of the aerosol-forming article.

Other layers may be present in addition to the first and second layers. For example, one or more additional layers may be present between the first and second layers, and/or outside the second layer. In some embodiments, the wrapping layer consists of the first and second layers, i.e., no other layers are present.

In some embodiments, the first layer consists of the non-combustible material. In this way, protection of the aerosol-forming substrate is increased.

In some embodiments, the second layer consists of the cellulosic material. In some embodiments, the cellulosic material comprises paper.

In some embodiments, the first layer and second layer are adhered to one another. In other words, the two layers are bound together by strong forces which does not permit easy separation of the layers. In this way, the structural integrity of the aerosol-forming article is increased.

In some embodiments, the non-combustible material comprises a metallic foil. In some embodiments, the metal in the metallic foil is aluminum. A metallic non-combustible material provides advantageous properties of resistance to ignition and/or combustion but also ductility, ease of availability and manufacture, good heat dissipation to the aerosol-forming substrate and a good substrate for applied flavorant. Importantly, the high thermal conductivity of metallic material means that a larger quantity of flavorant will be volatilized in circumstances when an aerosol-forming article is heated during use, thereby providing a more intense flavor experience for the user.

In some embodiments, an inner surface of the layer of non-combustible material adjacent to the aerosol-forming substrate carries the flavorant. In this way, flavorant is better placed to diffuse into and through the aerosol-forming substrate prior to and during use of the aerosol-forming article. For example, after manufacture and prior to use (e.g., during storage and shipment), flavorant will begin to diffuse into the aerosol-forming substrate thereby improving flavor during subsequent use. In addition, flavorant will diffuse directly into the aerosol forming substrate when heat is applied to the aerosol-forming article during use.

In some embodiments, the entire inner surface of the layer of non-combustible material adjacent to the aerosol-forming substrate carries flavorant. In some embodiments, the flavorant is evenly applied across the surface of the layer of non-combustible material. In this way, a smooth flavor experience can be provided for the user.

The flavorant may be applied to the layer of non-combustible material by any suitable coating method. In some embodiments, the flavorant (e.g., provided as a solution) is applied to a surface of the layer of non-combustible material by spraying. This provides an even coat and a means to more accurately control the quantity of flavorant applied in the coating and thereby the intensity of flavor delivered. This also provides a means to provide a varied concentration of flavorant across the surface of the non-combustible material layer. For example, it may be desirable to decrease the concentration of flavorant at a downstream location to prevent excessive flavor intensity, but to retain a higher concentration at an upstream location to ensure sufficient flavor.

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable.

The or at least one of the filter element(s) (e.g., the terminal filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element) may be comprised of paper. The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., any of the flavorants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET).

The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the wrapping layer. In some embodiments, the non-combustible material also covers at least a portion of the surface of the spacer element.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the fifth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the fifth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the fifth mode, there is provided a method of using a smoking substitute system according to the second aspect of the fifth mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the fifth mode may be applied to any other aspect of the fifth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the fifth mode and/or combined with any other feature or parameter described herein.

Sixth Mode: A Consumable Providing a Flavored Filter Element

At its most general, a sixth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable, comprising a flavored filter element.

According to a first aspect of the sixth mode, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate and at least one hollow bore filter element downstream from the aerosol-forming substrate wherein the at least one hollow bore filter element comprises a flavorant additive.

By providing at least one hollow bore filter with a flavorant additive, the user is provided with modified taste vapor that enhances the user experience. The presence of the hollow bore allows some vapor to pass through unflavored thus allowing a gentler ‘hit’ of flavorant.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the sixth mode.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The article/consumable may comprise a terminal hollow bore filter element with a flavorant additive at the downstream/mouth end of the article/consumable.

The article/consumable may comprise an upstream hollow bore filter element with a flavorant additive upstream from the downstream/mouth-end of the article/consumable e.g., axially adjacent and downstream of the aerosol-forming substrate.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

Where there is a terminal hollow bore filter element with a flavorant additive, there may be an upstream filter element which may be a flavored hollow bore filter element (as described above), an unflavored hollow bore filter element or a solid filter element (with or without flavorant additive).

Where there is an upstream hollow bore filter element with a flavorant additive, there may be a terminal filter element which may be a flavored hollow bore filter element (as described above), an unflavored hollow bore filter element or a solid filter element (with or without flavorant additive).

Where there are two filter elements, i.e., a terminal filter element and an upstream filter element, they may be axially adjacent one another or they may be axially spaced.

The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of cellulose acetate tow. The at least one filter element (e.g., the terminal filter element and/or upstream filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal filter element and/or upstream filter element) may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of extruded plant material, e.g., extruded tobacco. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of a polymer tow, e.g., polypropylene tow. The or each filter element (e.g., the terminal filter element and/or upstream filter element) may be circumscribed with a respective plug wrap e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The flavorant additive may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant additive may be evenly dispersed throughout the hollow bore filter element or may be provided in isolated locations and/or varying concentrations throughout the hollow bore filter element.

Where there is a solid terminal filter element or a solid upstream filter element, they may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., any of the flavorants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavorant. The capsule may be located at the axial center of the filter element.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m² e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt % e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream or terminal filter element and/or between the two (upstream and terminal) filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the article/consumable. For example, it may be between the aerosol-forming substrate and the upstream or terminal filter element and/or between the two (upstream and terminal) filter elements. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the sixth mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the sixth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the sixth mode, there is provided a method of using a smoking substitute system according to the second aspect of the sixth mode, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the sixth mode may be applied to any other aspect of the sixth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the sixth mode and/or combined with any other feature or parameter described herein.

Seventh Mode: A Consumable Providing Two Different Aerosol-Forming Materials

At its most general, a seventh mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising two different aerosol-forming materials.

According to a first aspect of the seventh mode, the present invention provides an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises at least one discrete region of a first aerosol-forming material within a matrix of a second aerosol-forming material.

By providing an aerosol-forming substrate having discrete regions of a first aerosol-forming material within a matrix of a second aerosol-forming material, the user experience can be tailored and thereby enhanced.

The two different aerosol-forming materials can be selected such that during the smoking of a single article/consumable the user is exposed to a mix of two vapors/aerosols having different properties, e.g., different flavors and/or different strengths of volatile compounds.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the seventh mode.

In some embodiments, there is a plurality of discrete regions of the first aerosol-forming material dispersed within the matrix of the second aerosol-forming material.

Reference to “discrete region(s)” of the first aerosol-forming material means that the concentration/dispersion of the first aerosol-forming material within the second aerosol-forming material is not uniform. This is in contrast to substrates formed from homogenized blends of two different types of aerosol-forming materials. Instead of being homogenized, the first aerosol-forming material is concentrated into one or more discrete regions within the second aerosol-forming material matrix.

The plurality of discrete regions of first aerosol-forming material may be evenly spaced within the matrix of the second aerosol-forming material. At least some and possibly all of the plurality of discrete regions of first aerosol-forming material may be entirely embedded within, i.e., entirely surrounded by the matrix of the second aerosol-forming material.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, each of the first and second aerosol-forming materials comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The first and/or second aerosol-forming material may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora inca mata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

In preferred embodiments, the first aerosol-forming material and the second aerosol-forming material each comprise tobacco which will contain nicotine as a volatile compound. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The second aerosol-forming material may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, shredded tobacco, homogenized tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon). In preferred embodiments, the second aerosol-forming material is reconstituted tobacco.

The first aerosol-forming material may comprise a different (relative to the first aerosol-forming material) one of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, shredded tobacco, homogenized tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The first aerosol-forming material preferably comprises extruded tobacco. For example, the first aerosol-forming material may comprise pellets, granules or chips of extruded tobacco. The extruded tobacco will provide a vapor having a higher nicotine content than the reconstituted tobacco.

Each pellet/chip/granule may form one of the plurality of discrete regions within the matrix of the first aerosol-forming material. In contrast to blends of different types of powdered tobacco, each pellet/chip/granule is of macroscopic size.

Extruded tobacco can be produced by forming a liquid mixture of powered tobacco and a binding agent such as a gum (e.g., xanthan, guar, Arabic and/or locust bean gum). The liquid mixture is heated and then extruded through a die. The extrudate is dried and then may be subsequently cut into pellets, chips or granules.

In some embodiments, the second aerosol-forming material comprises reconstituted tobacco and the first aerosol-forming material comprises extruded tobacco (e.g., pellet/chips/granules of extruded tobacco).

The aerosol-forming substrate, e.g., the second aerosol-forming material may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate (e.g., throughout the second aerosol-forming material) or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate/second aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., around 12 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable.

The or at least one of the filter element(s) (e.g., the terminal filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element) may be comprised of paper. The or each filter element may be at least partly (e.g., entirely) circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., a liquid flavorant as described above.

The capsule can be crushed by the user during smoking of the article/consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the article/consumable. The spacer element may comprise a cardboard tube. The spacer element may be circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the seventh mode, there is provided a smoking substitute system comprising an article/consumable according to the first aspect of the seventh mode and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the seventh mode, there is provided a method of using a smoking substitute system according to the second aspect of the seventh mode, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the seventh mode may be applied to any other aspect of the seventh mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the seventh mode and/or combined with any other feature or parameter described herein.

Eighth Mode: A Package for Aerosol-Forming Articles

At its most general, an eighth mode of the present disclosure relates to a package for aerosol-forming articles, e.g., a smoking substitute articles such as an HNB consumables comprising a flavorant.

According to a first aspect of the eighth mode, there is provided a packaging for a plurality of aerosol-forming articles, the packaging comprising: a base and an opposing lid spaced by one or more walls so as to define a cavity for the aerosol-forming articles; and an internal liner, the liner lining at least a portion of the one or more walls, wherein the packaging comprises a first flavorant source provided on the liner and a second flavorant source provided on pad disposed on an internal surface of the packaging.

The two flavorant sources will both impart flavor to the aerosol-forming articles, e.g., during transportation and/or storage. This may be in the form of additional flavoring (i.e., where the aerosol-forming articles already include a flavorant) or may be initial flavoring (i.e., where the aerosol-forming articles received in the packaging are (at least initially) non-flavored aerosol-forming articles). In the latter scenario, flavorant may not need to be added to the aerosol-forming articles during manufacture of the aerosol-forming articles, which may simplify the manufacture of the articles.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the eighth mode.

In some embodiments the internal liner lines the base, lid and one or more walls. In this way, the internal liner may enclose the aerosol-forming articles when received therein. The internal liner may be sealed, or sealable, such that the aerosol-forming articles may be sealed within the liner. The internal liner may comprise a flap moveable between an open position (exposing an opening in the internal liner) and a closed position (sealing the opening of the internal liner). The internal liner may be attached, e.g., adhered to one or more portions of the one or more walls, base and/or lid.

The internal surface of the liner may be sprayed, coated or impregnated with flavorant to provide the first flavorant source.

In some embodiments the liner may comprise a foil layer. The liner may additionally or alternatively comprise a paper layer. The liner may comprise a foil/paper laminate. The flavorant of the first flavorant source may be applied to the paper layer and/or the foil layer.

In some embodiments the pad providing the second flavorant source may be disposed on an internal surface of the lid or the base. Alternatively, or additionally, the pad may be provided on an internal surface of the liner lining the base or the lid. In these embodiments, the liner carries both the first flavorant source (e.g., as a coating) and the second flavorant source (e.g., on or in the pad). The pad may comprise a porous substrate which may be unfused/impregnated/sprayed or coated with flavorant.

In some embodiments the pad may be releasably mounted to the internal surface of the packaging, e.g., to the internal surface of the base/lid. In other words, the pad may be removable by, e.g., a user of the packaging. The pad may be mounted to the internal surface by way of an adhesive. Alternatively, the packaging may include means for mounting the pad. For example, the packaging may comprise a sleeve (e.g., on the base, lid, one or more walls, or internal liner) for receipt of the pad. The sleeve may comprise an opening so as to expose a portion of the pad to the internal cavity of the packaging. The pad may be mounted so as to be recessed into the internal surface on which it is mounted.

In some embodiments the internal pad may be arranged so as to contact the ends of the aerosol-forming articles when received in the cavity. The lid may be hingable between an open position and a closed position, and the internal pad (i.e., when disposed on the lid) may contact ends of the aerosol-forming articles when the lid is in the closed position. The lid may be configured so as to seal the aerosol-forming articles within the packaging (i.e., so as to retain released flavoring within the packaging).

Where the pad is disposed on the internal liner, the pad may be in contact with the aerosol-forming articles regardless of whether the lid is in the open or closed position. The internal liner may be unattached to the lid, such that opening of the lid does not affect the internal liner. Alternatively, the internal liner may be attached to the lid, such that opening the lid causes, e.g., a flap of the internal liner to open.

In some embodiments the pad may be substantially rectangular. The pad may alternatively be circular, triangular, elliptical, etc. The pad may have a thickness of between 0.5 mm and 3 mm or, e.g., between 1 mm and 2 mm.

In some embodiments the packaging may comprise a plurality of pads (e.g., two, three, four, etc. pads). Each pad may be in the form of a strip, and may be located on the internal surface of the packaging so as to correspond to a row of aerosol-forming articles contained in the cavity (i.e., such that the strips align with the ends of the articles). Alternatively, a pad may be provided for each aerosol-forming article received in the cavity and each pad may align with a respective end of an aerosol-forming article received in the cavity.

The flavorant provided by the first and second flavorant sources may be provided in solid (e.g., crystals) or liquid form. They may be independently selected from menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed on or in the internal liner and/or the pad, or may be provided in isolated locations and/or varying concentrations.

The flavorant in the first flavorant source may be the same as the flavorant in the second flavorant source.

The pad and/or liner may be configured such that the flavorant is released gradually. Alternatively, the pad and/or liner may be configured such the flavorant is released rapidly. In this respect, the pad and/or liner may be configured such that the flavorant is released for a predetermined amount of time. For example, the predetermined time may generally correspond to a transportation time of the packaging. That is, the pad and/or liner may be configured such that the flavorant is entirely (or substantially entirely) released during transportation of the packaging (i.e., after receipt of the aerosol-forming articles in the packaging, but before the packaging is opened by a user).

In some embodiments the pad may comprise a casing. The casing may be such that it encloses (or at least partially) encloses the pad. The casing may be releasable or openable (e.g., the casing may comprise a frangible portion) so as to expose the pad. In this way, the flavorant of the pad may be selectively released. That is, a user of the packaging may determine when the flavorant is to be released.

In some embodiments the pad may cover more than 10%, or, e.g., 15%, or, e.g., 20% of the internal surface area of the packaging. When disposed on the base, the pad may substantially cover the entire internal surface of the base. When disposed on the lid, the pad may substantially cover the entire internal surface of the lid.

In some embodiments the packaging may be substantially cuboid or boxed shape (i.e., the walls of the packaging may define a substantially rectangular transverse profile). The packaging may be configured to contain twenty aerosol-forming articles aligned longitudinally in the cavity.

The packaging may be configured to contain heat-not-burn (HNB) consumables. A HNB consumable may comprise an aerosol-forming substrate at an upstream end and a terminal filter at a downstream end. Hence, the substrate or terminal filter may be adjacent to (or in contact with) the pad and may thus acquire the flavor of the pad. The other of the terminal filter and substrate may be adjacent to (or in contact with) the internal liner and may thus acquire the flavor of the internal liner.

The packaging may have a width of between 50 mm and 120 mm, e.g., between 60 mm and 100 mm, e.g., around 70 mm. The packaging may have a depth of between 7 mm and 20 mm, e.g., between 10 mm and 18 mm, e.g., around 14 mm. The packaging may have a height of between 40 mm and 60 mm, e.g., between 45 mm and 55 mm, e.g., around 48 mm.

According a second aspect of the eighth mode, there is provided an aerosol-forming article package comprising: a base and an opposing lid spaced by one or more walls so as to define a cavity containing a plurality of aerosol-forming articles; and an internal liner lining at least a portion of the one or more walls wherein each article comprises an outer wrapper comprising a flavorant and wherein the internal liner comprises a flavorant.

Each aerosol-forming article may comprise an aerosol-forming substrate at an upstream end thereof. Each article may further comprise one or more of a terminal filter element at a downstream end, an upstream filter adjacent the substrate, a cooling element (e.g., between the terminal and upstream filter elements) and a spacer element (e.g., between the filter elements).

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapro/aerosol i.e. with the downstream end of each article being the mouth end or outlet where the aerosol exits the article for inhalation by the user. The upstream end of the article is the opposing end to the downstream end.

The outer wrapper of each article may comprise a wrapping layer (e.g., a paper wrapping layer) at least partly (e.g., fully) circumscribing the aerosol-forming substrate. The wrapping layer may further fully or partly circumscribe one or more of the filter element, aerosol-cooling element and spacer element. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with foil the innermost).

The wrapper layer of each article may extend for substantially the entire length of the article and in that respect may connect the elements (e.g., filters elements and substrate) of the article to one another.

In some embodiments, the outer wrapper of each article may further comprise a tipping layer (e.g., a tipping paper layer) at its axial downstream end which overlies a portion of the wrapping layer.

For example, in some embodiments, each article comprises a terminal filter element at the downstream axial end which may be joined to the upstream elements forming each article by the tipping (paper) layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

In some embodiments, each article comprises an upstream filter element (upstream of a downstream axial end of the article (e.g., upstream of the terminal filter element)). The upstream filter element of each article (which may be axially adjacent and downstream of the substrate) may be at least partly circumscribed by the wrapping layer.

In some embodiments, at least a portion of the wrapping layer and/or tipping paper of each article may be flavored.

In some embodiments, at least a portion of the tipping paper of each article may be flavored on its outer surface. The tipping paper of each article may be flavored on its outer surface at a portion closest to the downstream axial end of the article. The entire axial length of the tipping paper may be flavored on its outer surface.

In this way, as the user inhales on an article, in use, with the axial upstream end in their mouth, flavorant from the outer surface of tipping paper enters their mouth.

In some embodiments, at least a portion of the wrapping layer of each article may be flavored on its inner surface. The wrapping layer of each article may be flavored on its inner surface at a portion overlying one or more of the substrate, the upstream filter element, the cooling element, and the spacer element. The entire axial length of the wrapping layer of each article may be flavored on its inner surface.

In some embodiments the flavorant may coated, sprayed or painted onto the internal liner and/or the wrappers of the articles. In other embodiments the internal liner and/or the wrappers of the articles may be impregnated with the flavorant (e.g., the internal liner and/or wrapper of the articles may comprise a porous material for receipt of the flavorant).

The flavorant of the internal liner/and or the wrappers of the articles may be provided in solid (e.g., crystals) or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor.

In some embodiments each article may further comprise a flavorant additive (e.g., flavorant as described above) within one or more of the substrate, the filter element (e.g., the upstream and/or terminal filter element), the cooling element, and the spacer element. The flavorant may be provided in solid or liquid form. It may be provided in a frangible (e.g., meltable or crushable) capsule within one or more of the substrate, the filter element (e.g., the upstream and/or terminal filter element), and the cooling element. It may be provided as a flavored thread, e.g., a flavor-soaked cotton thread within one or more of the substrate, the filter element (e.g., the upstream and/or terminal filter element), and the cooling element. It may be provided as a coating on, or impregnated within, the spacer element.

In some embodiments the flavorant of the internal liner is the same as the flavorant of the wrapping layers of the articles. In other embodiments the flavorant of the internal liner may be different to the flavorant of the wrapping layers of the articles. The flavorant of one wrapping layer may be different to the flavorant of another of the wrapping layers. In other words, the package may comprise a plurality of articles of different flavors.

The package may otherwise be as described with respect to the packaging of the first aspect of the eighth mode. For example, the package may further comprise a pad as described above. In this way, flavorant may be provided by the wrappers of the articles, the liner, and a pad. The internal liner of the package may be as otherwise described with respect to the packaging of the first aspect of the eighth mode.

The aerosol-forming articles may be smoking substitute articles (e.g., such as heat-not-burn (HNB) consumables). Each aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate of each article/consumable is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate of each article/consumable may be located at the upstream end of the article/consumable.

In order to generate an aerosol, the aerosol-forming substrate of each article/consumable comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate of each article/consumable may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (SkulIcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate of each article/consumable may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate of each article/consumable has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate of each article/consumable may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate of each article/consumable may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate of each article/consumable may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate of each article/consumable may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate of each article/consumable, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate of each article/consumable. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate of each article/consumable. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate of each article/consumable, e.g., around 6 to 9 wt %.

The aerosol-forming substrate of each article/consumable may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate of each article/consumable has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant in the aerosol-forming substrate of each article/consumable may be provided in solid or liquid form. The flavorant may comprise one or more of the flavors discussed above with respect to the wrappers, internal liner and pad. The flavorant may be evenly dispersed throughout the aerosol-forming substrate of each article/consumable or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate of each article/consumable may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/upstream filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of paper. The at least one filter element (e.g., the terminal element/upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a solid filter element. The or at least one of the filter element(s) (e.g., the terminal filter element/upstream filter element) may be a hollow bore filter element. The or each hollow bore filter element may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The aerosol-cooling element of each article/consumable may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element of each article/consumable may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The spacer element of each article/consumable may act to allow both cooling and mixing of the aerosol. The spacer element of each article/consumable may be a tubular spacer element, e.g., it may comprise a cardboard tube. The spacer element of each article/consumable may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element of each article/consumable may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a third aspect of the eighth mode there is disclosed a method of forming a flavored aerosol-forming article. The method comprises providing a packaging according to the first aspect of the eighth mode, and sealing an unflavored aerosol-forming article within the packaging for a period of time such that the aerosol-forming article acquires the flavor of the first and/or second flavorant source.

The packaging may be as described above with respect to the first and second aspects of the eighth mode.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the eighth mode may be applied to any other aspect of the eighth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the eighth mode and/or combined with any other feature or parameter described herein.

Ninth Mode: A Consumable Providing an Additive Carrier Downstream of an Aerosol-Forming Substrate

At its most general, a ninth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising an additive carrier downstream of an aerosol-forming substrate.

According to a first aspect of the ninth mode, the present invention provides an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate wherein the article further comprises an additive carrier downstream and adjacent the aerosol-forming substrate.

By providing an aerosol-forming substrate and a downstream additive carrier with the additive carrier immediately adjacent the aerosol-forming substrate, upon release of the additive from the liquid carrier, the additive can wick into the aerosol-forming substrate so that the additive can modify the vapor released from the substrate and thus tailor/enhance the user experience.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the ninth mode.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol i.e. with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

The additive carrier is preferably held in abutment/contact with the substrate such that during use, release of the additive from the additive carrier results in wicking of the additive into the substrate. Accordingly, the additive carrier may be in direct contact/abutment with the aerosol-forming substrate.

In some embodiments, the additive carrier is housed in a cavity which is downstream and axially adjacent the aerosol-forming substrate. The cavity will be dimensioned such that the additive carrier is held in abutment/contact (e.g., direct abutment/contact with the downstream end of the aerosol-substrate.

In other embodiments, the additive carrier may be embedded in a filter element positioned axially adjacent the aerosol-forming substrate. It will be embedded at the upstream axial end of the filter element.

The additive carrier may a capsule or micro-molding. The additive carrier may have an outer shell which may be solid/rigid. The outer shell may be crushable or meltable to release the additive from the additive carrier. The additive carrier may be substantially spherical. Additive carriers typically known as “crush balls” can be used.

The additive carrier may carry a liquid additive. The additive may be selected from (liquid) humectants or flavorants.

Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). Inclusion of a humectant in the additive carrier within the cavity allows the generation of an increased amount of visible vapor potentially at lower temperatures.

The flavorant may be provided in solid or liquid form within the additive carrier. It may include menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco, and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed/dosed throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm.

It may have an axial length of between 10 and 15 mm.

The cavity may have an axial length of around 3 to 7 mm, e.g., 3, 3.5, or 4 mm.

The aerosol-forming substrate and cavity may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable. There may be a filter element adjacent the aerosol-forming substrate which may include the additive carrier.

The or at least one of the filter element(s) (e.g., the terminal filter element/the additive carrier carrying filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element/the additive carrier carrying filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element/the additive carrier carrying filter element) may be comprised of paper. The or each filter element may be at least partly (e.g., entirely) circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., a liquid flavorant as described above. The capsule can be crushed by the user during smoking of the consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. The spacer element may comprise a cardboard tube. The spacer element may be circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the ninth mode, there is provided a system comprising an article/consumable according to the first aspect of the ninth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the ninth mode, there is provided a method of using a system according to the second aspect of the ninth mode, the method comprising: inserting the article/consumable into the device; and heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The method preferably further comprises rupturing the additive carrier during heating of the article/consumable to release a liquid additive for wicking into the aerosol-forming substrate.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the ninth mode may be applied to any other aspect of the ninth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the ninth mode and/or combined with any other feature or parameter described herein.

Tenth Mode: A Consumable Providing Liquid-Containing Capsule that can be Ruptured Mechanically by a Heater Element

At its most general, a tenth mode of the present disclosure relates to an aerosol-forming article, e.g., a smoking substitute article such as an HNB consumable comprising a liquid-containing capsule that can be ruptured mechanically by a heater element.

According to a first aspect of the tenth mode, the present invention provides an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate wherein the article further comprises a liquid pod enclosed within the aerosol-forming substrate and adapted to be ruptured mechanically upon coupling with a heating element.

By providing an aerosol-forming substrate having a liquid pod that can be ruptured by a heating element, the liquid within the liquid pod can be released without user intervention, e.g., without the user having to locate and crush the liquid pod. The liquid can be released simply upon coupling of the consumable with the heating element. Upon release of the liquid from the liquid carrier, the liquid can wick into the surrounding aerosol-forming substrate so that the liquid can modify the vapor released from the substrate and thus tailor/enhance the user experience.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the tenth mode.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol i.e. with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

The liquid pod may be embedded within the aerosol-forming substrate or may be housed within a cavity in the aerosol-forming substrate.

The liquid pod may have an outer shell which may be solid/rigid. The outer shell may be crushable, breakable or penetrable by the heating element. The liquid pod may be substantially spherical. Liquid pods typically known as “crush balls” can be used.

The liquid pod may carry a liquid vapor modifier. The vapor modifier may comprise one or more humectant or and/or a flavorant.

Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). Inclusion of a humectant in the liquid pod within the cavity allows the generation of an increased amount of visible vapor potentially at lower temperatures.

The flavorant may include menthol, liquorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor.

The liquid pod will be spaced from the upstream end of the aerosol-forming substrate by a distance that is less than the penetration depth of the heating element within the aerosol-forming substrate. This may mean that the liquid pod is closer to the upstream axial end of the aerosol-forming substrate than the downstream end.

For example, the penetration depth may be around 12 mm and so the liquid pod may be spaced from the upstream end of the aerosol-forming substrate by a distance of less than 12 mm, e.g., by a distance of 10 mm or less, e.g., 9 or 8 mm or less, e.g., by a distance of 7 or 6 mm or less. It may be spaced from the upstream axial end of the aerosol-forming substrate by an amount of 1 or 2 mm or more, e.g., by an amount of 3 or 4 or 5 mm or more. For example, it may be spaced form the axial upstream end by an amount between 1 and 12 mm, e.g., between 2 and 10 mm, such as between 3 and 8 mm, for example between 4 and 7 mm or between 5 and 6 mm.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip). Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized (e.g., paper/slurry recon) tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed/dosed throughout the aerosol-forming substrate.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm.

It may have an axial length of between 10 and 15 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable.

The or at least one of the filter element(s) (e.g., the terminal filter element) may be comprised of cellulose acetate or polypropylene tow. The at least one filter element (e.g., the terminal filter element) may be comprised of activated charcoal. The at least one filter element (e.g., the terminal element) may be comprised of paper. The or each filter element may be at least partly (e.g., entirely) circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., a liquid flavorant as described above. The capsule can be crushed by the user during smoking of the consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. The spacer element may comprise a cardboard tube. The spacer element may be circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the tenth mode, there is provided a system comprising an article/consumable according to the first aspect of the tenth mode and a device comprising a penetrating heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into a cavity within the main body for receiving the article/consumable.

The spacing of the liquid pod from the upstream end of the article/consumable is less than the axial length of the heating element (or less than the length that the heating element projected into the cavity) such that upon penetration of the aerosol-forming substrate by the heating element, the liquid pod is mechanically crushed/broken/penetrated by the heating element to release the liquid from the liquid pod into the aerosol-forming substrate.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the tenth mode, there is provided a method of using a system according to the second aspect of the tenth mode, the method comprising:

inserting the article/consumable into the device such that the heating element penetrates the article and mechanically ruptures the liquid pod; and heating the article/consumable using the heating element.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the tenth mode may be applied to any other aspect of the tenth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the tenth mode and/or combined with any other feature or parameter described herein.

Eleventh Mode: A Consumable Providing an Increased Concentration of Volatile Compound

At its most general, an eleventh mode of the present disclosure relates to an aerosol-forming article, e.g., an HNB consumable having an increased concentration of volatile compound.

According to a first aspect of the eleventh mode, the present invention provides an aerosol-forming article (e.g., an HNB consumable) comprising an aerosol-forming substrate dosed with a coating of flavorant, wherein the aerosol-forming substrate is a slurry-type reconstituted plant material, and wherein the flavorant content is up to 20% by weight of the aerosol-forming substrate.

Reference to “slurry-type” corresponds to a reconstituted plant material made by slurry-casting as opposed to a paper-making process.

By using an aerosol-forming substrate (which will itself include a volatile compound) dosed with a coating of flavorant, the number/concentration of volatile compound(s) can be increased to provide the user with a vapor/aerosol containing a higher concentration of the volatile compound(s). This may provide the user with an enhanced recreational and/or medicinal effect when inhaled. In particular, the user experiences an enhanced flavor. Also, a coating provides an even application of flavorant to the aerosol-forming substrate, therefore providing the user with a more consistent experience.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the eleventh mode.

The aerosol-forming article is preferably a heat-not-burn (HNB) consumable.

The aerosol-forming substrate is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the article/consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol, i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the article/consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

In some embodiments, the flavorant is a non-tobacco flavorant. Advantageously, as the invention is primarily intended to provide a substitute smoking consumable, the use of non-tobacco flavors provides the user with unconventional flavors, which are not typically experienced. Therefore, a varied and enhanced user experience is provided.

The aerosol-forming substrate comprises plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise a gathered sheet of homogenized slurry recon tobacco or gathered shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

In some embodiments, the sheet used to form the aerosol-forming substrate has a density of less than 1100 mg/cm³, preferably less than 1000 mg/cm³, and more preferably less than 900 mg/cm³.

In some embodiments, the sheet used to form the aerosol-forming substrate has a mass/surface area of less than 0.09 mg/mm², preferably less than 0.085 mg/mm², preferably less than 0.08 mg/mm² and more preferably less than 0.075 mg/mm².

In some embodiments the aerosol-forming substrate may have a thickness less than about 1 mm, preferably less than about 0.5 mm, preferably between about 0.1 and 0.3 mm, such as about 0.2 mm.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The aerosol-forming substrate may comprise one or more additives selected from humectants, fillers, aqueous/non-aqueous solvents and binders.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and carboxymethyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 20 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %. The upper limit of binder is preferably up to 15 wt. %, such as up to 10 wt. %. Preferably the binder content is above 5 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, peppermint, spearmint, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) coffee, Eucalyptus, and tobacco flavor. The flavorant may be evenly dispersed as a coating on the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations as a coating on the aerosol-forming substrate. Preferably the flavorant is evenly dispersed as a coating on the aerosol-forming substrate.

The flavorant is provided as a coating on the aerosol-forming article. Such a coating is provided on the aerosol-forming article by surface application of a liquid comprising the flavorant. For example, application by brushing, spraying, or immersion into the liquid. It is preferred that the coating is uniform across the surface of the aerosol-forming article.

In preferred embodiments the coating is provided to the sheet of slurry-type reconstituted plant material from which the aerosol-forming article is formed. The coating may be provided to both major surfaces of the sheet, or, alternatively, just to one major surface of the sheet. In preferred embodiments the coating is provided on the sheet of slurry-type reconstituted plant material before the sheet is divided, e.g., by shredding or slitting, to form the aerosol-forming article. In some embodiments the coating is substantially continuous across the surface of the sheet or the aerosol-forming article when applied.

While the coating is applied to the surface of the aerosol-forming article, in some cases the flavorant penetrates into a surface layer of the aerosol-forming article. Preferably the flavorant is present in a surface layer of the aerosol-forming article only, i.e., not throughout the aerosol-forming article. Advantageously, these flavorants are found to be desired by the user, and also provide the user with a satisfactory flavor “hit”. In addition, a varied and enhanced flavor experience is achieved.

The dosed flavorant content of the aerosol-forming substrate may have a lower limit of at least 0.1 wt % of the weight of the aerosol-forming substrate, such as at least 0.5 wt %, such as at least 1 wt %, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %.

The dosed flavorant content of the aerosol-forming substrate may have an upper limit of at most 20 wt % of the aerosol-forming substrate, such as at most 15 wt %, such as at most 10 wt %.

Preferably, the flavorant concentration is 0.1 to 15 wt %. Even more preferred is a flavorant concentration of 0.1 to 5 wt % of the aerosol-forming substrate.

Preferably, the flavorant is menthol.

It is further preferred that the flavorant is synthetically derived menthol. Advantageously, this source of menthol is not naturally derived. Typically, naturally derived menthol is provided in the form of mint or mint extracts. Consequently, the use of synthetic menthol excludes the presence of undesired components present in mint or mint extracts.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the article/consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The article/consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the article/consumable. There may be a plurality of filter elements (e.g., the terminal filter element and an upstream filter element) which may be adjacent one another or which may be spaced apart. Any upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element) may be comprised of cellulose acetate tow. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element may be comprised of activated charcoal. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal filter element and/or upstream filter element may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal filter element (at the downstream end of the article/consumable) may be joined to the upstream elements forming the article/consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., any of the flavorants listed above. The capsule can be crushed by the user during smoking of the article/consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In some embodiments, the article/consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The article/consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the article/consumable. It may be provided between the aerosol-forming substrate and the upstream filter element and/or between the two filter elements. The spacer element may comprise a tubular element, e.g., a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the eleventh mode, there is provided a smoking substitute system comprising an aerosol-forming article according to the first aspect of the eleventh mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the article/consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a third aspect of the eleventh mode, there comprises a method of using a smoking substitute system according to the second aspect of the eleventh mode, the method comprising:

inserting the article/consumable into the device; and

heating the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

In a fourth aspect of the eleventh mode, there is provided a method for manufacturing an aerosol-forming substrate, wherein the aerosol forming substrate is a slurry-type reconstituted plant material comprising: combining a ground plant material with an aqueous medium to form a slurry; casting the slurry on a surface to form a sheet; and applying a flavorant to the sheet to provide a coating.

Advantageously, by applying flavorant to the sheet as a coating a more even application of flavorant on the aerosol-forming substrate is achieved as compared to provision of flavorant as or in a separate component or constituent of the aerosol-forming substrate or of the article/consumable. This provides the user with enhanced flavor and a more consistent flavor experience. Also, the application of flavorant to the sheet may be carried out in a secondary environment away from the main line of manufacturing. Therefore, contamination on the main line apparatus with undesired flavorant is avoided. Therefore, in some embodiments it is preferred to apply the flavorant after winding of the sheet onto a bobbin, for example by unwinding the sheet from the bobbin before application of the flavorant. Advantageously, this application of flavorant may take place after transport of the sheet (e.g., wound onto a bobbin) to a location remote from the casting location.

It is preferable that the plant material is ground to a particle size of less than 120 microns. It is undesirable to have a particle size greater than 150 microns as this is associated with the formation of defects and inhomogeneous areas in the sheet formed by casting the slurry. Particularly, preferred is a particle size of 30 to 120 microns.

A binder may also be included within the slurry. The amount of binder used is chosen to provide an amount of 5 to 20 weight % of binder in the sheet ultimately produced from the slurry, such as 5 to 15 weight %, such as 5 to 10 weight %. The ground tobacco may be combined with the binder before combination with the aqueous medium. Or alternatively, the binder may be combined with the aqueous medium prior to combining the aqueous medium with the ground tobacco.

The slurry may also contain fillers, humectants, preservatives, and/or flavors. These may be combined with the ground plant material before combination with the aqueous medium, or alternatively can be added to the slurry separately

It is preferred that the total solids content of the slurry is between 15% and 30% of the total slurry weight. Of this preferred range about 50 to 90% of the total solids content of the slurry should be the plant material. The plant material content of the slurry is not critical, but it is preferred that the minimum amount of aqueous medium is used to avoid leaching of plant material solubles into the aqueous medium.

The slurry is formed by mixing the various components of the slurry. This may be achieved using a high energy mixer or a high shear mixer to homogenize the slurry. During mixing the slurry may optionally be heated.

Additionally, the slurry may be vibrated to aid homogenization of the slurry. This may be achieved by vibrating a tank or silo in which the slurry is contained.

After mixing the slurry is cast onto a moving support surface, such as a dryer belt to form a sheet. Casting of the sheet may be achieved by a roll coater system or a laminator, or any other method suitable in the art. It is preferred that the moisture content of the sheet at casting is between 60 and 80 percent of the total weight of the cast slurry. The cast sheet is then dried by exposure to elevated temperatures and/or reduced pressures to remove excess moisture content from the sheet. Suitable drying methods include a steam dryer and/or heated air dryers. Alternatively, the sheet may be dried under ambient conditions,

Preferably, the flavorant is applied by spray-coating.

Advantageously, by applying the flavorant to the cast sheet by spray-coating a more uniform application of flavorant is achieved to provide a more homogeneous product. Accordingly, a more consistent user experience results.

Preferably, the flavorant is a non-tobacco flavor. In particular, the flavorant is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavor, vanilla, spice, coffee, Eucalyptus, and tobacco flavor. In particular, the flavorant is synthetically derived menthol. The advantages of which flavorants is described above.

Preferably, the plant material is tobacco.

As the invention is primarily intended to provide a smoking consumable, the use of tobacco provides a slurry-type reconstituted plant material having the inherent properties of tobacco, for examples, the texture, aroma and nicotine content.

Preferably, the method of the fourth aspect of the eleventh mode comprises a step of drying the sheet, wherein the flavorant is applied to the sheet after drying.

Advantageously, as many flavorants exhibit high volatility, the application of the flavoring after drying the sheet avoids loss of flavorant by evaporation when drying at elevated temperatures or at reduced pressures.

Preferably, the method of the fourth aspect of the eleventh mode comprises a step of winding the sheet onto a bobbin, wherein the flavorant is applied to the sheet after winding.

Advantageously, this facilitates efficient storage of the sheet and allows the flavorant to be applied in a secondary environment that is separate from the main line of manufacturing. Thereby avoiding contamination of the main line apparatus with undesired flavor.

Alternatively, the flavorant may be applied to the sheet before winding of the sheet onto the bobbin.

Preferably, the method of the fourth aspect of the eleventh mode includes a step of making an HNB consumable from the sheet.

According to a fifth aspect of the eleventh mode there is provided an aerosol-forming substrate for an HNB device produced by the process according to the fourth aspect of the eleventh mode.

Preferably, the aerosol-forming substrate according to the fifth aspect of the eleventh mode has a dosed flavorant content of 0.1 to 20% by weight of the aerosol-forming substrate.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the eleventh mode may be applied to any other aspect of the eleventh mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the eleventh mode and/or combined with any other feature or parameter described herein.

Twelfth Mode: A Consumable Providing Aerosol-Forming Substrate Having an Increased Concentration of Volatile Compound

At its most general, a twelfth mode of the present disclosure relates to method of forming an HNB consumable comprising an aerosol-forming substrate having an increased concentration of volatile compound.

According to a first aspect of the twelfth mode, the present invention provides a method of forming an HNB consumable comprising an aerosol-forming substrate, the method comprising a slurry-type process for forming a reconstituted plant material, wherein a flavorant is provided in the slurry prior to casting into a sheet.

Reference to “slurry-type” corresponds to a reconstituted plant material made by slurry-casting as opposed to a paper-making process.

By using an aerosol-forming substrate (which will itself include a volatile compound) dosed with a flavorant, the number/concentration of volatile compound(s) can be increased to provide the user with a vapor/aerosol containing a higher concentration of the volatile compound(s). This may provide the user with an enhanced recreational and/or medicinal effect when inhaled. Also, current flavoring options for HNB consumables is limited. Therefore, by dosing the aerosol-forming substrate with flavorant the user will experience an enhanced and varied flavor from the resultant HNB consumable.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the twelfth mode.

The method of the first aspect for manufacturing a heat-not-burn (HNB) consumable comprising an aerosol-forming substrate, wherein the aerosol forming substrate is a slurry-type reconstituted plant material, comprises the steps of: combining a ground plant material with an aqueous medium to form a slurry; providing a flavorant in the slurry; casting the slurry to form a sheet; drying the sheet to form an aerosol-forming substrate; and incorporating a portion of the aerosol-forming substrate into an HNB consumable.

The aerosol-forming substrate formed by the present methods is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol, i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational aid/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

A binder may also be included within the slurry. Therefore, the methods may further comprise a step of incorporating a binder into the slurry. The ground tobacco may be combined with the binder before combination with the aqueous medium. Or alternatively, the binder may be combined with the aqueous medium prior to combining the aqueous medium with the ground tobacco.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and carboxymethyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder is included at a level to result in the binder content being 5 to 20 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %. The upper limit of binder is preferably up to 15 wt. %, such as up to 10 wt. %. Preferably the binder content is above 5 wt %.

The slurry may also contain fillers, humectants, and/or preservatives. These may be combined with the ground plant material before combination with the aqueous medium, or alternatively can be added to the slurry separately.

It is preferred that the total solids content of the slurry is between 15% and 30% of the total slurry weight. Of this preferred range about 50 to 90% of the total solids content of the slurry should be the plant material. The plant material content of the slurry is not critical, but it is preferred that the minimum amount of aqueous medium is used to avoid leaching of plant material solubles into the aqueous medium.

The slurry is formed by mixing the various components of the slurry. This may be achieved using a high energy mixer or a high shear mixer to homogenize the slurry. During mixing the slurry may optionally be heated.

Additionally, the slurry may be vibrated to aid homogenization of the slurry. This may be achieved by vibrating a tank or silo in which the slurry is contained.

After mixing the slurry is cast onto a moving support surface, such as a dryer belt to form a sheet. Casting of the sheet may be achieved by a roll coater system or a laminator, or any other method suitable in the art. It is preferred that the moisture of the sheet at casting is between 60 to 80 percent of the total weight of the cast slurry. The cast sheet is then dried, for example by exposure to elevated temperatures and/or reduced pressures to remove excess moisture content from the sheet. Suitable drying methods include a steam dryer and/or heated air dryers. Alternatively, the sheet may be dried under ambient conditions,

The flavorant may be provided in solid or liquid form. It may include menthol, peppermint, spearmint, licorice, chocolate, fruit flavor (including, e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon), coffee, Eucalyptus, and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate. Preferably the flavorant is evenly dispersed in the slurry resulting in an even dispersion throughout the aerosol-forming substrate. The ability to evenly disperse the flavorant throughout the aerosol-forming substrate is one benefit of the present methods. The result of this is an improved user experience and uniformity of flavor profile.

Advantageously, these flavorants are found to be desired by the user, and also provide the user with a satisfactory flavor “hit”. In addition, a varied and enhanced flavor experience is achieved.

The dosed flavorant content of the aerosol-forming substrate may have a lower limit of at least 0.1 wt % of the weight of the aerosol-forming substrate, such as at least 0.5 wt %, such as at least 1 wt %, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %.

The dosed flavorant content of the aerosol-forming substrate may have an upper limit of at most 20 wt % of the aerosol-forming substrate, such as at most 15 wt %, such as at most 10 wt %.

Preferably, the flavorant concentration is 0.1 to 15 wt %. Even more preferred is a flavorant concentration of 0.1 to 5 wt % of the aerosol-forming substrate.

Preferably, the flavorant is menthol.

It is further preferred that the flavorant is synthetically derived menthol. Advantageously, this source of menthol is not naturally derived. Typically, naturally derived menthol is provided in the form of mint or mint extracts. Consequently, the use of synthetic menthol excludes the presence of undesired components present in mint or mint extracts.

Advantageously, as the invention is primarily intended to provide a method useful in formation of a substitute smoking consumable, the use of non-tobacco flavors provides the user with unconventional flavors, which are not typically experienced. Therefore, a varied and enhanced user experience is provided.

Preferably the flavorant is provided in a base liquid. Advantageously, by “pre-mixing” the flavorant with a base liquid prior to combining the “pre-mixture” with a slurry provides a safer, efficient and reproducible delivery of flavorant to the slurry. In particular, the pre-mixing of the flavorant with a base liquid reduces the volatility of the flavorant making it easier to handle and process. In addition, the benefit of the resultant HNB consumable is that it avoids exposure of the user to harmful combustion products when using the consumable, but without loss of flavor.

Preferable base liquids are polyhydric alcohols. Suitable polyhydric alcohols include propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). In particular, propylene glycol and vegetable glycerine are preferred.

Preferably, the dosed flavorant content contained within the base liquid is within the range 1 to 95 wt % based on the total weight of flavorant and base liquid.

It is particularly preferred to have a flavorant content of 1 to 50 wt %, such as 1 to 25 wt. %, such as 1 to 15 wt % of the total weight flavorant and base liquid. Advantageously, this provides sufficient dilution of flavorant with base liquid to provide safer handling of the flavorant during processing. Also, such a combination allows for good dispersion of flavorant within the base liquid.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamoto (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (SkulIcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

Preferably, the plant material is tobacco.

As the invention is primarily intended to provide a smoking consumable, the use of tobacco provides a slurry-type reconstituted plant material having the inherent properties of tobacco, for examples, the texture, aroma and nicotine content.

It is preferable that the plant material is ground to a particle size of less than 120 microns. It is undesirable to have a particle size greater than 150 microns as this is associated with the formation of defects and inhomogeneous areas in the sheet formed by casting the slurry. Particularly, preferred is a particle size of 30 to 120 microns.

The method may comprise a step of winding the formed sheet onto a bobbin. The method may further comprise gathering the sheet of homogenized slurry recon tobacco or gathering shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

In some embodiments, the sheet used to form the aerosol-forming substrate has a density of less than 1100 mg/cm³, preferably less than 1000 mg/cm³, and more preferably less than 900 mg/cm³.

In some embodiments, the sheet used to form the aerosol-forming substrate has a mass/surface area of less than 0.09 mg/mm², preferably less than 0.085 mg/mm², preferably less than 0.08 mg/mm² and more preferably less than 0.075 mg/mm².

In some embodiments the aerosol-forming substrate may have a thickness less than about 1 mm, preferably less than about 0.5 mm, preferably between about 0.1 and 0.3 mm, such as about 0.2 mm.

The step of casting the slurry to form a sheet may therefore comprise spreading the slurry to form a sheet which, when dried, has a thickness and/or density as set out herein.

The aerosol-forming substrate may additionally comprise one or more additives selected from humectants, fillers, aqueous/non-aqueous solvents and binders provided during the formation method, e.g., provided in the slurry.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the consumable. There may be an upstream filter element which may be axially adjacent or axially spaced from the terminal filter element. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of cellulose acetate tow. The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of activated charcoal. The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

The terminal filter element (at the downstream end of the consumable) may be joined to the upstream elements forming the consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., any of the flavorants listed above. The capsule can be crushed by the user during smoking of the consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In some embodiments, the consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the twelfth mode there is provided an HNB consumable formed by a method according to the first aspect of the twelfth mode.

In a third aspect of the twelfth mode, there is provided a smoking substitute system comprising an HNB consumable according to the second aspect of the twelfth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fourth aspect of the twelfth mode, there comprises a method of using a smoking substitute system according to the third aspect of the twelfth mode, the method comprising: inserting the HNB consumable into the device; and heating the HNB consumable using the heating element.

In some embodiments, the method comprises inserting the HNB consumable into a cavity within the main body and penetrating the HNB consumable with the heating element upon insertion of the HNB consumable. For example, the heating element may penetrate the aerosol-forming substrate in the HNB consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the twelfth mode may be applied to any other aspect of the twelfth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the twelfth mode and/or combined with any other feature or parameter described herein.

Thirteenth Mode: A Consumable Providing an Aerosol-Forming Substrate Having an Increased Concentration of Volatile Compound

At its most general, a thirteenth mode of the present disclosure relates to method of forming an HNB consumable comprising an aerosol-forming substrate having an increased concentration of volatile compound.

According to a first aspect of the thirteenth mode, the present invention provides a method of forming an HNB consumable comprising an aerosol-forming substrate, the method comprising a slurry-type process for forming a reconstituted plant material, wherein a casing is provided in the slurry prior to casting into a sheet.

Reference to “slurry-type” corresponds to a reconstituted plant material made by slurry-casting as opposed to a paper-making process.

By using an aerosol-forming substrate (which will itself include a volatile compound) dosed with a casing, the user is provided with an enhanced flavor profile. This is advantageous in light of the limited current flavor profile options for HNB consumables. The addition of casing, particularly sugar, to the aerosol-forming substrate also negates the reliance on the natural sugar content of the tobacco plant, therefore an aerosol-forming substrate with increased sugar content is provided. Inclusion of a casing component in the aerosol-forming substrate of an HNB consumable can be beneficial to mitigate negative qualities of plant material, for example reduction in the alkalinity of a resultant aerosol (associated with “tongue bite”) or mellowing of harsh or ashy flavors.

Optional features will now be set out. These are applicable singly or in any combination with any aspect of the thirteenth mode.

The method of the first aspect of the thirteenth mode for manufacturing a heat-not-burn (HNB) consumable comprising an aerosol-forming substrate, wherein the aerosol forming substrate is a slurry-type reconstituted plant material, comprises the steps of: combining a ground plant material with an aqueous medium to form a slurry; providing a casing component in the slurry; casting the slurry to form a sheet; drying the sheet to form an aerosol-forming substrate; and incorporating a portion of the aerosol-forming substrate into an HNB consumable.

The aerosol-forming substrate formed by the present methods is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol, i.e., with the downstream end of the consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the consumable is the opposing end to the downstream end.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, caffeine, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Casing components are known in the tobacco industry and are defined herein as a component which enhances the flavor profile and/or user experience when used in an HNB consumable. Casing components preferably differ from flavorants, i.e., they preferably do not themselves provide any significant new flavor to the aerosol produced by the aerosol-forming substrate. Casings may be used to mitigate negative qualities of plant material, for example reduction in the alkalinity of a resultant aerosol (associated with “tongue bite”) or mellowing of harsh or ashy flavors.

The casing component may be one or more selected from sugars and non-sugar casings. Preferably the casing component comprises a sugar. In some embodiments the casing component consists essentially of one or more sugars. In some embodiments the casing component consists of one or more sugars and one or more non-sugar casings. The sugar may be selected from sucrose, fructose, lactose, glucose, dextrose, mannose, galactose, rhamnose, maltose and xylose, and combinations thereof. Alternatively, or additionally, the sugar may be selected from natural, unrefined sugars, for example maple sugar, cane sugar, molasses, date sugar, honey, agave nectar, and brown rice syrup.

Non-sugar casings may be selected from cocoa, carob bean extract, licorice, fruit extracts.

Advantageously, the use of a casing component comprising a sugar provides the user with an enhanced flavor experience.

The casing component is provided in the slurry at a level suitable to result in a content in the dried aerosol-forming substrate of up to 20 wt. %. Preferably the content in the dried aerosol-forming substrate may have a lower limit of at least 2 wt % of the weight of the aerosol-forming substrate, such as at least 3 wt %, such as at least 4 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt % m such as at least 20 wt %.

Preferably the casing component content in the dried aerosol-forming substrate may have an upper limit of at most 25 wt %, such as at most 20 wt %, such as at most 15 wt %, or such as at most 10 wt %.

Preferably, the casing component content is 0.1 to 15 wt % of the aerosol-forming substrate.

Preferably the casing component is provided in a base liquid. Advantageously, by “pre-mixing” the casing component with a base liquid prior to combining the “pre-mixture” with a slurry provides a safer, efficient and reproducible delivery of casing component to the slurry.

Preferably the casing component is soluble in the base liquid.

Preferable base liquids are water and polyhydric alcohols. Suitable polyhydric alcohols include propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). In particular, propylene glycol and vegetable glycerin are preferred.

In some embodiments the base liquid is water. Advantageously, the non-toxicity and non-flammability of water minimizes handling risks during processing. Furthermore, the “premixing” of the casing component with a solvent prior to combination with the slurry, improves the homogeneous nature of the casing component and the slurry mixture.

Preferably, the dosed casing content contained within the base liquid is within the range 1 to 95 wt % based on the total weight of casing and base liquid.

It is particularly preferred to have a casing content of 1 to 50 wt %, such as 1 to 25 wt. %, such as 1 to 15 wt % of the total weight casing and base liquid. Advantageously, this provides sufficient dilution of casing with base liquid to provide safer handling of the casing during processing. Also, such a combination allows for good dispersion of casing within the base liquid.

When the casing component comprises more than one constituent component, it is preferably provided in the form of a “pre-mixed” casing mixture. Advantageously, by providing the casing in the form of a “pre-mixed” casing the physical and organoleptic properties of the aerosol-substrate are improved due to increased homogeneity of the casing components to provide a balanced flavor and consistent user experience.

The addition of the casing component to the slurry provides a greater degree of homogeneity of the casing and plant material components. This provides the user with improved flavor profile and a more consistent experience when using the resultant HNB consumable. The quantity of casing can also be tailored to provide bespoke blends of casing and plant material that are tailored to meet the user's requirements.

A binder may also be included within the slurry. Therefore, the methods may further comprise a step of incorporating a binder into the slurry. The ground tobacco may be combined with the binder before combination with the aqueous medium. Or alternatively, the binder may be combined with the aqueous medium prior to combining the aqueous medium with the ground tobacco.

Suitable binders are known in the art and may act to bind together the components forming the aerosol-forming substrate. Binders may comprise starches and/or cellulosic binders such as methyl cellulose, ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and carboxymethyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder is included at a level to result in the binder content being 5 to 20 wt % of the aerosol-forming substrate, e.g., around 6 to 8 wt %. The upper limit of binder is preferably up to 15 wt. %, such as up to 10 wt. %. Preferably the binder content is above 5 wt %.

The slurry may also contain fillers, humectants, flavorants and/or preservatives. These may be combined with the ground plant material before combination with the aqueous medium, or alternatively can be added to the slurry separately.

It is preferred that the total solids content of the slurry is between 15% and 30% of the total slurry weight of this preferred range about 50 to 90% of the total solids content of the slurry should be the plant material. The plant material content of the slurry is not critical, but it is preferred that the minimum amount of aqueous medium is used to avoid leaching of plant material solubles into the aqueous medium.

The slurry is formed by mixing the various components of the slurry. This may be achieved using a high energy mixer or a high shear mixer to homogenize the slurry. During mixing the slurry may optionally be heated.

Additionally, the slurry may be vibrated to aid homogenization of the slurry. This may be achieved by vibrating a tank or silo in which the slurry is contained.

After mixing the slurry is cast onto a moving support surface, such as a dryer belt to form a sheet. Casting of the sheet may be achieved by a roll coater system or a laminator, or any other method suitable in the art. It is preferred that the moisture of the sheet at casting is between 60 to 80 percent of the total weight of the cast slurry. The cast sheet is then dried, for example by exposure to elevated temperatures and/or reduced pressures to remove excess moisture content from the sheet. Suitable drying methods include a steam dryer and/or heated air dryers. Alternatively, the sheet may be dried under ambient conditions, In embodiments where the slurry includes a flavorant, the flavorant may be provided in solid or liquid form. It may include menthol, peppermint, spearmint, licorice flavor, chocolate flavor, fruit flavor (including, e.g., citrus, cherry etc.), vanilla flavor, spice flavor (e.g., ginger, cinnamon), coffee flavor, Eucalyptus flavor, and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate. Preferably the flavorant is evenly dispersed in the slurry resulting in an even dispersion throughout the aerosol-forming substrate.

The dosed flavorant content of the aerosol-forming substrate may have a lower limit of at least 0.1 wt % of the weight of the aerosol-forming substrate, such as at least 0.5 wt %, such as at least 1 wt %, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 15 wt %.

The dosed flavorant content of the aerosol-forming substrate may have an upper limit of at most 20 wt % of the aerosol-forming substrate, such as at most 15 wt %, such as at most 10 wt %.

Preferably, the flavorant concentration is 0.1 to 15 wt %. Even more preferred is a flavorant concentration of 0.1 to 5 wt %. of the aerosol-forming substrate.

Preferably, the flavorant is menthol.

Preferably the flavorant is provided in a base liquid. Advantageously, by “pre-mixing”the flavorant with a base liquid prior to combining the “pre-mixture” with a slurry provides a safer, efficient and reproducible delivery of flavorant to the slurry.

Preferable base liquids for flavorants are polyhydric alcohols. Suitable polyhydric alcohols include propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerine (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). In particular, propylene glycol and vegetable glycerine are preferred.

Preferably, the dosed flavorant content contained within the base liquid is within the range 1 to 95 wt % based on the total weight of flavorant and base liquid.

It is particularly preferred to have a flavorant content of 1 to 50 wt %, such as 1 to 25 wt. %, such as 1 to 15 wt % of the total weight flavorant and base liquid. Advantageously, this provides sufficient dilution of flavorant with base liquid to provide safer handling of the flavorant during processing. Also, such a combination allows for good dispersion of flavorant within the base liquid.

The aerosol-forming substrate may comprise at least 50 wt % plant material, e.g., at least 60 wt % plant material, e.g., around 65 wt % plant material. The aerosol-forming substrate may comprise 80 wt % or less plant material, e.g., 75 or 70 wt % or less plant material.

The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Amica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia californica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

Preferably, the plant material is tobacco.

As the invention is primarily intended to provide a smoking consumable, the use of tobacco provides a slurry-type reconstituted plant material having the inherent properties of tobacco, for examples, the texture, aroma, flavor and nicotine content.

It is preferable that the plant material is ground to a particle size of less than 120 microns. It is undesirable to have a particle size greater than 150 microns as this is associated with the formation of defects and inhomogeneous areas in the sheet formed by casting the slurry. Particularly, preferred is a particle size of 30 to 120 microns.

The method may comprise a step of winding the formed sheet onto a bobbin.

The method may further comprise gathering the sheet of homogenized slurry recon tobacco or gathering shreds/strips formed from such a sheet.

In some embodiments, the sheet used to form the aerosol-forming substrate has a grammage greater than or equal to 100 g/m², e.g., greater than or equal to 110 g/m² such as greater than or equal to 120 g/m².

The sheet may have a grammage of less than or equal to 300 g/m², e.g., less than or equal to 250 g/m² or less than or equal to 200 g/m².

The sheet may have a grammage of between 120 and 190 g/m².

In some embodiments, the sheet used to form the aerosol-forming substrate has a density of less than 1100 mg/cm³, preferably less than 1000 mg/cm³, and more preferably less than 900 mg/cm³.

In some embodiments, the sheet used to form the aerosol-forming substrate has a mass/surface area of less than 0.09 mg/mm², preferably less than 0.085 mg/mm², preferably less than 0.08 mg/mm² and more preferably less than 0.075 mg/mm².

In some embodiments the aerosol-forming substrate may have a thickness less than about 1 mm, preferably less than about 0.5 mm, preferably between about 0.1 and 0.3 mm, such as about 0.2 mm.

The step of casting the slurry to form a sheet may therefore comprise spreading the slurry to form a sheet which, when dried, has a thickness and/or density as set out herein.

The aerosol-forming substrate may additionally comprise one or more additives selected from humectants, flavorants, fillers, aqueous/non-aqueous solvents and binders provided during the formation method, e.g., provided in the slurry.

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), triethylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between land 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable fillers are known in the art and may act to strengthen the aerosol-forming substrate. Fillers may comprise fibrous (non-tobacco) fillers such as cellulose fibers, lignocellulose fibers (e.g., wood fibers), jute fibers and combinations thereof.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate, e.g., around 6 to 9 wt %.

The aerosol-forming substrate may comprise an aqueous and/or non-aqueous solvent. In some embodiments, the aerosol forming substrate has a water content of between 5 and 10 wt %, e.g., between 6-9 wt % such as between 7-9 wt %.

25 The aerosol-forming substrate may be formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It may have a diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 11 and 14 mm such as around 12 or 13 mm.

The aerosol-forming substrate may be circumscribed by a wrapping layer, e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

The consumable may comprise at least one filter element. There may be a terminal filter element at the downstream/mouth end of the consumable. There may be an upstream filter element which may be axially adjacent or axially spaced from the terminal filter element. The upstream filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of cellulose acetate tow. The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of activated charcoal. The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of paper. The or at least one of the filter element(s) (e.g., the terminal filter element and/or the upstream filter element) may be comprised of plant material, e.g., extruded plant material. The or each filter element may be circumscribed with a plug wrap, e.g., a paper plug wrap.

The or each filter element may have a substantially cylindrical shape with a diameter substantially matching the diameter of the aerosol-forming substrate (with or without its associated wrapping layer). The axial length of the or each filter element may be less than 20 mm, e.g., between 8 and 15 mm, for example between 9 and 13 mm, e.g., between 10 and 12 mm.

The or at least one of the filter element(s) may be a solid filter element. The or at least one of the filter element(s) may be a hollow bore filter element. The or each hollow bore filter may have a bore diameter of between 1 and 5 mm, e.g., between 2 and 4 mm or between 2 and 3 mm.

There may be a plurality of, e.g., two filter elements which may be adjacent one another or which may be spaced apart. Any filter element(s) upstream of the terminal filter element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The terminal filter element (at the downstream end of the consumable) may be joined to the upstream elements forming the consumable by a circumscribing tipping layer, e.g., a tipping paper layer. The tipping paper may have an axial length longer than the axial length of the terminal filter element such that the tipping paper completely circumscribes the terminal filter element plus the wrapping layer surrounding any adjacent upstream element.

The or at least one of the filter elements, e.g., the terminal filter element may include a capsule, e.g., a crushable capsule (crush-ball) containing a liquid flavorant, e.g., any of the flavorants listed above. The capsule can be crushed by the user during smoking of the consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In some embodiments, the consumable may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element will be downstream from the aerosol-forming substrate. For example, it may be between the aerosol-forming substrate and a/the filter element and/or between two filter elements. The aerosol cooling element may be at least partly (e.g., completely) circumscribed by the (paper) wrapping layer.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET).

The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The consumable may comprise a spacer element that defines a space or cavity between the aerosol-forming substrate and the downstream end of the consumable. The spacer element may comprise a cardboard tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

The spacer element may have an external diameter of between 5 and 10 mm, e.g., between 6 and 9 mm or 6 and 8 mm, e.g., around 7 mm. It may have an axial length of between 10 and 15 mm, e.g., between 12 and 14 mm or 13 and 14 mm, e.g., around 14 mm.

In a second aspect of the thirteenth mode there is provided an HNB consumable formed by a method according to the first aspect of the thirteenth mode.

In a third aspect of the thirteenth mode, there is provided a smoking substitute system comprising an HNB consumable according to the second aspect of the thirteenth mode and a device comprising a heating element.

The device may be a HNB device, i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated, e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply, e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a fourth aspect of the thirteenth mode, there comprises a method of using a smoking substitute system according to the third aspect of the thirteenth mode, the method comprising: inserting the HNB consumable into the device; and heating the HNB consumable using the heating element.

In some embodiments, the method comprises inserting the HNB consumable into a cavity within the main body and penetrating the HNB consumable with the heating element upon insertion of the HNB consumable. For example, the heating element may penetrate the aerosol-forming substrate in the HNB consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects of the thirteenth mode may be applied to any other aspect of the thirteenth mode. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect of the thirteenth mode and/or combined with any other feature or parameter described herein.

SUMMARY OF THE FIGURES

So that the invention may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the invention will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1 shows a first embodiment of the first mode of an HNB consumable;

FIG. 2 shows a second embodiment of the first mode of an HNB consumable;

FIG. 3 shows a third embodiment of the first mode of an HNB consumable; and

FIG. 4 shows the first embodiment of the first mode within a device forming an HNB system.

FIG. 5 shows a first embodiment of the second mode of an HNB consumable.

FIG. 6 shows the terminal filter element of the first embodiment of the second mode.

FIG. 7 shows the first embodiment of the second mode within a device forming an HNB system.

FIG. 8 shows a first embodiment of the third mode of an HNB consumable.

FIG. 9 shows a second embodiment of the third mode of an HNB consumable.

FIG. 10 shows a third embodiment of the third mode of an HNB consumable.

FIG. 11 shows the first embodiment of the third mode within a device forming an HNB system.

FIG. 12 shows a first embodiment of the fourth mode of an HNB consumable.

FIG. 13 shows a second embodiment of the fourth mode of an HNB consumable.

FIG. 14 shows a third embodiment of the fourth mode of an HNB consumable.

FIG. 15 shows the first embodiment of the fourth mode within a device forming an HNB system.

FIG. 16 shows a cross-sectional view of a first embodiment of the fifth mode of an HNB consumable.

FIG. 17 shows a cross-sectional view of a second embodiment of the fifth mode of an HNB consumable.

FIG. 18 shows a cross-sectional view of a third embodiment of the fifth mode of an HNB consumable.

FIG. 19 shows a cross-sectional view of a fourth embodiment of an HNB consumable.

FIG. 20 shows a cross-sectional view of the first embodiment of the fifth mode within a device forming an HNB system.

FIG. 21 shows a perspective view of the first embodiment of the fifth mode with the paper wrapper layer cut away.

FIG. 22 shows a close-up view of the upstream axial end of the first embodiment of the fifth mode.

FIG. 23 shows a first embodiment of the sixth mode of an HNB consumable.

FIG. 24 shows a second embodiment of the sixth mode of an HNB consumable.

FIG. 25 shows a third embodiment of the sixth mode of an HNB consumable.

FIG. 26 shows the first embodiment of the sixth mode within a device forming an HNB system.

FIG. 27 shows a first embodiment of the seventh mode of an HNB consumable.

FIG. 28 shows a second embodiment of the seventh mode of an HNB consumable.

FIG. 29 shows a third embodiment of the seventh mode of an HNB consumable.

FIG. 30 shows the first embodiment of the seventh mode within a device forming an HNB system.

FIG. 31 shows a first embodiment of the eighth mode of an HNB consumable package.

FIG. 32 shows a second embodiment of the eighth mode of an HNB consumable package.

FIG. 33 shows a third embodiment of the eighth mode of an HNB consumable package.

FIG. 34 shows a first embodiment of the eighth mode of a HNB consumable.

FIG. 35 shows a second embodiment of the eighth mode of a HNB consumable.

FIG. 36 shows a first embodiment of the ninth mode of an HNB consumable.

FIG. 37 shows a second embodiment of the ninth mode of an HNB consumable.

FIG. 38 shows a third embodiment of the ninth mode of an HNB consumable.

FIG. 39 shows the first embodiment of the ninth mode within a device forming an HNB system.

FIG. 40 shows a first embodiment of the tenth mode of an HNB consumable.

FIG. 41 shows a second embodiment of the tenth mode of an HNB consumable.

FIG. 42 shows a third embodiment of the tenth mode of an HNB consumable.

FIG. 43 shows the first embodiment of the tenth mode within a device forming an HNB system.

FIG. 44 shows a first embodiment of the eleventh mode of an HNB consumable.

FIG. 45 shows a second embodiment of the eleventh mode of an HNB consumable.

FIG. 46 shows a third embodiment of the eleventh mode of an HNB consumable.

FIG. 47 shows the first embodiment of the eleventh mode within a device forming an HNB system.

FIG. 48 shows an illustrative diagram of an embodiment of the manufacturing process of the eleventh mode.

FIG. 49 shows a first embodiment of the twelfth mode of an HNB consumable formed by the present methods.

FIG. 50 shows a second embodiment of the twelfth mode of an HNB consumable formed by the present methods.

FIG. 51 shows a third embodiment of the twelfth mode of an HNB consumable formed by the present methods.

FIG. 52 shows the first embodiment within a device forming an HNB system of the twelfth mode.

FIG. 53 shows an illustrative diagram of an embodiment of the present methods of the twelfth mode.

FIG. 54 shows a first embodiment of the thirteenth mode of an HNB consumable formed by the present methods.

FIG. 55 shows a second embodiment of the thirteenth mode of an HNB consumable formed by the present methods.

FIG. 56 shows a third embodiment of the thirteenth mode of an HNB consumable formed by the present methods.

FIG. 57 shows the first embodiment within a device forming an HNB system of the thirteenth mode.

FIG. 58 shows an illustrative diagram of an embodiment of the present methods of the thirteenth mode.

DETAILED DESCRIPTION OF THE FIGURES

First Mode: A Consumable Providing at Least One Flavored Sleeve Downstream of an Aerosol Forming Substrate

As shown in FIG. 1, the HNB consumable 10 comprises an aerosol-forming substrate 14 at the upstream end of the HNB consumable 10.

The aerosol-forming substrate 14 comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm. The cavity 13 has an axial length of around 4 mm.

The aerosol-forming substrate 14 is circumscribed by a paper wrapping layer 18.

The HNB consumable 10 comprises an upstream filter element 22 and a downstream (terminal) filter element 26. The two filter elements 22, 26 and spaced by a cardboard spacer tube 30. Both filter elements 22, 26 are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter element 22 matches the diameter of the aerosol-forming substrate 14. The diameter of the terminal filter element 26 is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 and the paper wrapping layer 18. The upstream filter element 22 is slightly shorter in axial length than the terminal filter element 26 at an axial length of 10 mm compared to 12 mm for the terminal filter element 26.

The upstream filter element 22 contains an embedded crush ball 34 (i.e., a spherical capsule with a solid, crushable outer wall) containing menthol flavorant. The crush ball 34 has a diameter of around 3.5 mm and is positioned at the axial center of the upstream filter element 22. The upstream filter element 22 is circumscribed by a tubular flavored paper sleeve 38 which is impregnated with menthol flavorant.

The cardboard tube spacer 30 a is longer than each of the two filter portions having an axial length of around 14 mm.

The terminal filter element 26 is a hollow bore filter element with a hollow, longitudinally extending bore having a diameter of 2 mm.

The cardboard spacer tube 30, the upstream filter element 22, and the flavored sleeved 38 are circumscribed by the paper wrapping layer 18.

The terminal filter element 26 is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42. The paper tipping layer 42 encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 a.

FIG. 2 shows a second embodiment of a HNB consumable 10′ which is the same as that shown in FIG. 1 except that the crush ball 34 embedded at the axial center of a terminal filter element 26′ which is a solid filter element whilst the upstream filer element 22′ is a hollow bore filter element having a bore diameter of 3 mm.

FIG. 3 shows a third embodiment of a HNB consumable 10″ which is the same as that shown in FIG. 1 except that the upstream filer element 22′ is a hollow bore filter element having a bore diameter of 3 mm without any crush ball 34 and the terminal filter element 26 is a hollow bore filter element having a bore diameter of 2 mm. The terminal filter element 26 is circumscribed by a second tubular flavored paper sleeve 46 which is impregnated with menthol flavorant.

FIG. 4 shows a fourth embodiment of a HNB consumable 10′″ which is the same as the first embodiment except that the paper wrapping layer 18 does not completely circumscribe the cardboard spacer tube 30 such that there is an annular gap 50 between the paper tipping layer 42 and the cardboard spacer tube 30 downstream of the end of the paper wrapping layer 18.

FIG. 4 shows the first embodiment inserted into an HNB device 54 comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 58 within a main body 62 of the device.

The HNB consumable 10 is inserted into the cavity 58 of the main body 62 of the device 54 such that the heating rod penetrates the aerosol-forming substrate 14. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 26.

The crush ball 34 containing VG can be ruptured by pressure to allow the VG to wick into the aerosol-forming substrate to modify the amount of visible vapor during smoking of the consumable. As the vapor cools within the upstream filter element 22 and the cardboard spacer tube 30, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Second Mode: A Consumable Providing an Unimpeded Flow Passage Around a Filter Element

As shown in FIG. 5, an HNB consumable 10 a comprises an aerosol-forming substrate 14 a at the upstream end of the HNB consumable 10 a.

The aerosol-forming substrate 14 a comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 14 a comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 a is formed in a substantially cylindrical shape such that the consumable 10 a resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 a is circumscribed by a paper wrapping layer 18 a.

The HNB consumable 10 a comprises an upstream filter element 22 a and a downstream (terminal) filter element 26 a. The two filter elements 22 a, 26 a and spaced by a cardboard tube spacer 30 a. Both filter elements 22 a, 26 a are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements have a substantially cylindrical shape. The diameter of the upstream filter element 22 a matches the diameter of the aerosol-forming substrate 14 a. The upstream filter element 22 a is slightly shorter in axial length than the terminal filter element 26 a at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 a.

The cardboard tube spacer 30 a is longer than each of the two filter elements 22 a, 26 a having an axial length of around 14 mm.

The upstream filter element 22 a is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 22 a is around 3 mm.

The cardboard tube spacer 30 a and the upstream filter element 22 a are circumscribed by the paper wrapping layer 18 a.

The terminal filter element 26 a is a solid filter and has a corrugated outer surface 86 a (discussed below) comprising a series of longitudinally-extending channels 74 a. The terminal filter element 26 a is circumscribed by a paper sleeve 70 a which lies against the peaks of the corrugations on the outer surface of the terminal filter element 26 a but leaves the longitudinally-extending channels 74 a unimpeded.

The terminal filter element 26 a is joined to the upstream elements forming the HNB consumable 10 a by a circumscribing paper tipping layer 42 a. The paper tipping layer 42 a encircles the terminal filter element 26 a (and the paper sleeve 70 a) and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 a.

The terminal filter element 26 a comprises a longitudinally-extending thread 78 a soaked with a liquid menthol or cherry or vanilla flavorant. It is positioned along the axial center of the terminal filter element 26 a.

FIG. 6 shows an exploded view of the terminal filter element 26 a comprising a plug wrap 82 a which has corrugations matching those in the corrugated outer surface 86 a of the terminal filter element 26 a. The paper sleeve 70 a overlays the corrugated outer surface 86 a and plug wrap 82 a and rests against the peaks in the corrugations leaving the longitudinally-extending channels 74 a unimpeded. The paper tipping layer 42 a circumscribes the paper sleeve 70 a.

FIG. 7 shows the second embodiment inserted into an HNB device 54 a comprising a rod-shaped heating element 90 a. The heating element 90 a projects into a cavity 58 a within the main body 62 a of the device 54 a.

The HNB consumable 10 a is inserted into the cavity 58 a of the main body 62 a of the device 54 a such that the heating rod 90 a penetrates the aerosol-forming substrate 14 a. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 a is effected by powering the heating element (e.g. with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compounds (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter element 26 a.

As the vapor cools within the upstream filter element 22 a and the cardboard tube spacer 30 a, the vapor condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Some of the aerosol passes through the terminal filter element 26 a where it is flavored by the flavorant-soaked longitudinally-extending thread 78 a. The remainder of the aerosol passes unimpeded through the longitudinally-extending channels 74 a in the corrugated outer surface 86 a of the filter element 26 a thus increasing the visible vapor at the downstream axial end (mouth-end) of the consumable.

Third Mode: A Consumable Providing a Spacer Element Adapted to Impart Flavor to the Vapor/Aerosol

As shown in FIG. 8, the HNB consumable 10 b comprises an aerosol-forming substrate 14 b at the upstream end of the consumable 10 b.

The aerosol-forming substrate 14 b comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 14 b comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 14 b further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 b is formed in a substantially cylindrical shape such that the consumable 10 b resembles a conventional cigarette. The consumable 10 b has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 b is circumscribed by a paper wrapping layer 18 b.

The consumable 10 b comprises an upstream filter element 22 b and a downstream (terminal) filter element 26 b. The two filter elements 22 b, 26 b and spaced by a cardboard tube spacer 30 b. Both filter elements 22 b, 26 b are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 b, 26 b have a substantially cylindrical shape. The diameter of the upstream filter element 22 b matches the diameter of the aerosol-forming substrate 14 b. The diameter of the terminal downstream filter element 26 b is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 b and the paper wrapping layer 18 b. The upstream filter element 22 b is slightly shorter in axial length than the terminal downstream filter element 26 b at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 b.

The cardboard tube spacer 30 b is longer than each of the two filter elements 22 b, 26 b having an axial length of around 14 mm. It is coated with a layer of menthol flavorant 13.

Each filter element 22 b, 26 b is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 22 b is slightly larger than the diameter of the bore in the terminal filter 26 b having a diameter of 3 mm compared to 2 mm for the terminal downstream filter element 26 b.

The cardboard tube spacer 30 b and the upstream filter element 22 b are circumscribed by the paper wrapping layer 18 b.

The terminal downstream filter element 26 b is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 b. The tipping layer 42 b encircles the terminal downstream filter element 26 b and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 b.

FIG. 9 shows a second embodiment of a consumable 10 b′ which is the same as that shown in FIG. 8 except that the terminal downstream filter element 26 b is a solid filter element and comprises a crushable capsule 34 b (crush-ball 34 b) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 b is spherical and has a diameter of 3.5 mm. The capsule 34 b is positioned within the axial center of the terminal downstream filter element 26 b. Furthermore, the cardboard tube spacer 30 b′ is impregnated with menthol, cherry or vanilla flavorant.

FIG. 10 shows a third embodiment of a consumable 10 b″ which is the same as the first embodiment except that the tube spacer 30 b″ is formed of an extruded plastic tube and the paper wrapping layer 18 b does not completely circumscribe the tube spacer 30 b″ such that there is an annular gap 50 b between the tipping layer 42 b and the cardboard tube spacer 30 b″ downstream of the end of the paper wrapping layer 18 b.

The coated cardboard tube spacer 30 b of FIG. 8, the impregnated cardboard tube spacer 30 b′ and the coated extruded plastic tube 30 b″ are all interchangeable.

FIG. 11 shows the first embodiment of FIG. 8 inserted into an HNB device 54 b comprising a rod-shaped heating element 90 b. The heating element 90 b projects into a cavity 58 b within the main body 62 b of the device.

The consumable 10 b is inserted into the cavity 58 b of the main body 62 b of the device 54 b such that the heating rod 90 b penetrates the aerosol-forming substrate 14 b. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 b is effected by powering the heating element 90 b (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compounds (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal downstream filter element 26 b.

The menthol coating 100 on the cardboard tube spacer 30 b prevents imparts menthol flavor to the aerosol/vapor prior to the terminal filter element for inhalation by the user.

Fourth Mode: A Consumable Providing an Aerosol-Forming Substrate at the Upstream End of the Consumable

As shown in FIG. 12, the HNB consumable 10 c comprises an aerosol-forming substrate 14 c at the upstream end of the consumable 10 c.

The aerosol-forming substrate 14 c comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 14 c comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. Prior to shredding, the sheet of recon tobacco is sprayed with menthol flavorant additive so that the substrate 14 c has menthol flavorant additive equally distributed throughout. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 c is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 c is circumscribed by a paper wrapping layer 18 c.

The consumable 10 c comprises an upstream filter element 22 c and a downstream (terminal) filter element 26 c. The two filter elements 22 c, 26 c and spaced by a cardboard tube spacer 30 c. Both filter elements 22 c, 26 c are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 c, 26 c have a substantially cylindrical shape. The diameter of the upstream filter element 22 c matches the diameter of the aerosol-forming substrate 14 c. The diameter of the terminal filter element 26 c is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 c and the wrapping layer 18 c. The upstream filter element 22 c is slightly shorter in axial length than the terminal filter element 26 c at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 c.

The cardboard tube spacer 30 c is longer than each of the two filter elements 22 c, 26 c having an axial length of around 14 mm.

Each filter element 22 c, 26 c is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 22 c is slightly larger than the diameter of the bore in the terminal filter element 26 c having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 c.

The cardboard tube spacer 30 c and the upstream filter element 22 c are circumscribed by the wrapping layer 18 c.

The terminal filter element 26 c is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 c. The tipping layer 42 c encircles the terminal filter element 26 c and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 c. The outer surface of the tipping layer 42 c is coated with menthol flavorant.

FIG. 13 shows a second embodiment of a consumable 10 c′ which is the same as that shown in FIG. 12 except that the terminal filter element 26 c is a solid filter element and comprises a crushable capsule 34 c (crush-ball 34 c) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 c is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter element 26 c. Furthermore, instead of the tipping paper 42 c being flavored on its outer surface, the wrapping layer 18 c is flavored on its inner surface in the portion 104 a, overlying the aerosol-forming substrate 14 c.

FIG. 14 shows a third embodiment of a consumable 10 c″ which is the same as the first embodiment except that the wrapping layer 18 c does not completely circumscribe the cardboard tube spacer 30 c such that there is an annular gap 50 c between the tipping layer 42 c and the cardboard tube spacer 30 c downstream of the end of the wrapping layer 18 c. Furthermore, instead of flavorant within the substrate, the cardboard tube spacer 30 c is impregnated with liquid menthol flavorant.

FIG. 15 shows the first embodiment inserted into an HNB device 54 c comprising a rod-shaped heating element 90 c. The heating element 90 c projects into a cavity 58 c within the main body 62 c of the device 54 c.

The consumable 10 c is inserted into the cavity 58 c of the main body 62 c of the device 54 c such that the heating rod 90 c penetrates the aerosol-forming substrate 14 c. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 c is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco, the humectant and menthol flavorant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter element 26 c.

As the vapor cools within the upstream filter element 22 c and the cardboard tube spacer 30 c, the vapor condenses to form an aerosol containing the volatile compounds for inhalation by the user.

The menthol flavorant on the outer surface of the tipping paper 42 c is delivered to the user's mouth during inhalation (by virtue of inserting the terminal filter element 26 c into their mouth) thus further enhancing the menthol flavor perceived by the user.

Fifth Mode: A Consumable Providing a Means to Prevent Ignition of the Article and Provide Flavor

As shown in FIG. 16, the HNB consumable 10 d comprises an aerosol-forming substrate 14 d at the upstream end of the consumable 10 d.

The aerosol-forming substrate 14 d comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 14 d comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 d is formed in a substantially cylindrical shape such that the consumable 10 d resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 d is circumscribed by a layer of aluminum foil 108 a, which in turn is circumscribed by a paper wrapping layer 18 d. The aerosol-forming substrate is therefore circumscribed by a laminate wrapper comprising two layers: the inner aluminum foil layer 108 a and the outer paper layer 108 b. The inner surface of the aluminum foil layer 108 a carries menthol flavorant which is applied by spray coating prior to assembly of the consumable. The layer of aluminum foil 108 a extends to cover the curved external surface of the aerosol-forming substrate 14 d but does not cover any of the planar circular end face of the aerosol-forming substrate 14 d.

The consumable 10 d comprises an upstream filter element 22 d and a downstream (terminal) filter element 26 d. The two filter elements 22 d, 26 d are spaced by a cardboard tube spacer 30 d. Both filter elements 22 d, 26 d are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 d, 26 d have a substantially cylindrical shape. The diameter of the upstream filter 22 d matches the diameter of the aerosol-forming substrate 14 d. The diameter of the terminal filter element 26 d is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 d and the wrapping layer 18 d. The upstream filter element 22 d is slightly shorter in axial length than the terminal filter element 26 d at an axial length of 10 mm compared to 12 mm for the terminal filer element 26 d.

The cardboard tube spacer is longer than each of the two filter elements having an axial length of around 14 mm.

Each filter element 22 d, 26 d is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 22 d is slightly larger than the diameter of the bore in the terminal filter 26 d having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 d.

The cardboard tube spacer 30 d and the upstream filter element 22 d are circumscribed by the wrapping layer 18 d.

The terminal filter element 26 d is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 d. The tipping layer 42 d encircles the terminal filter element 26 d and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 d.

FIG. 17 shows a second embodiment of a consumable 10 d′ which is the same as that shown in FIG. 16 except that the aluminum foil layer 108 a extends to circumscribe not only the aerosol-forming substrate 14 d but also the upstream filter element 22 d.

FIG. 18 shows a third embodiment of a consumable 10 d″ which is the same as that shown in FIG. 16 except that the terminal filter element 26 d is a solid filter element and comprises a crushable capsule 34 d (crush-ball 34 d) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 d is spherical and has a diameter of 3.5 mm. The capsule 34 d is positioned within the axial center of the terminal filter element 26 d.

FIG. 19 shows a fourth embodiment of a consumable 10 d′″ which is the same as the first embodiment except that the wrapping layer 18 d does not completely circumscribe the cardboard tube spacer 30 d such that there is an annular gap 50 d between the tipping layer 42 d and the cardboard tube spacer 30 d downstream of the end of the wrapping layer 18 d.

FIG. 20 shows the first embodiment inserted into an HNB device 54 d comprising a rod-shaped heating element 90 d. The heating element 90 d projects into a cavity 58 d within the main body 62 d of the device 54 d.

The consumable 10 d is inserted into the cavity 58 d of the main body 62 d of the device 54 d such that the heating rod 90 d penetrates the aerosol-forming substrate 14 d. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 d is effected by powering the heating element (e.g., with a rechargeable battery (not shown)).

As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter element 26 d. Additionally, the menthol present within the coating applied to the inner surface of the aluminum foil layer 108 a is volatilized and becomes entrained within the airflow to provide flavor to the user.

As the vapor cools within the upstream filer element 22 d and the cardboard tube spacer 30 d, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

FIG. 21 shows a perspective view of the structure of the wrapping layer 18 d in the first embodiment. The wrapping layer 18 d consists of the inner aluminum foil layer 108 a and the outer paper layer 108 b. The layer of aluminum foil 108 a extends to cover only the curved surface of the aerosol-forming substrate 14 d, without extending to cover the adjacent upstream filter element 22 d or the planar circular end-surface of the aerosol-forming substrate 14 d. The paper wrapping layer 18 d then lies over the entire length of the consumable 10 d, including the aluminum foil layer 108 a.

FIG. 22 is a close-up view of the upstream end of the first embodiment shown in FIG. 21.

Sixth Mode: A Consumable Providing a Flavored Filter Element

As shown in FIG. 23, the HNB consumable 10 e comprises an aerosol-forming substrate 14 e at the upstream end of the consumable 10 e.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 14 e comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate 14 e further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 e is formed in a substantially cylindrical shape such that the consumable 10 e resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 e is circumscribed by a paper wrapping layer 18 e.

The consumable 10 e comprises an upstream filter element 22 e and a downstream (terminal) filter element 26 e. The two filter elements 22 e, 26 e and spaced by a cardboard tube spacer 30 e. Both filter elements 22 e, 26 e are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 e, 26 e have a substantially cylindrical shape. The diameter of the upstream filter 22 e matches the diameter of the aerosol-forming substrate 14 e. The diameter of the terminal filter element 26 e is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 e and the wrapping layer 18 e. The upstream filter element 22 e is slightly shorter in axial length than the terminal filter element 26 e at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 e.

The cardboard tube spacer 30 e is longer than each of the two filter elements 22 e, 26 e having an axial length of around 14 mm.

Each filter element 22 e, 26 e is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 22 e is slightly larger than the diameter of the bore in the terminal filter 26 e having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 e.

The cardboard tube spacer 30 e and the upstream filter element 22 e are circumscribed by the wrapping layer 18 e.

The terminal filter element 26 e is joined to the upstream elements forming the consumable 10 e by a circumscribing paper tipping layer 42 e. The tipping layer 42 e encircles the terminal filter element 26 e and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 e.

The terminal hollow bore filter element 26 e is dosed with liquid menthol flavorant additive.

FIG. 24 shows a second embodiment of a consumable 10 e′ which is the same as that shown in FIG. 23 except that the terminal filter element 26 e′ is a solid filter element and comprises a crushable capsule 34 e (crush-ball 34 e) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 e is spherical and has a diameter of 3.5 mm. The capsule 34 e is positioned within the axial center of the terminal filter element 26 e′. In this embodiment, the upstream filter element 22 e′ is dosed with liquid flavorant which may or may not be the same flavor as the flavorant in the crush-ball 34 e.

FIG. 25 shows a third embodiment of a consumable 10 e″ which is the same as the first embodiment except that the wrapping layer 18 e does not completely circumscribe the cardboard tube spacer 30 e such that there is an annular gap 50 e between the tipping layer 42 e and the cardboard tube spacer 30 e downstream of the end of the wrapping layer 18 e. In this embodiment, both the upstream hollow bore filter 22 e′ and the terminal hollow bore filter 26 e are dosed with liquid flavorant which may or may not be the same.

FIG. 26 shows the first embodiment inserted into an HNB device 54 e comprising a rod-shaped heating element 90 e. The heating element 90 e projects into a cavity 58 e within the main body 62 e of the device 54 e.

The consumable 10 e is inserted into the cavity 58 e of the main body 62 e of the device 54 e such that the heating rod 90 e penetrates the aerosol-forming substrate 14 e. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 e is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter element 26 e.

As the vapor cools within the upstream filter element 22 e and the cardboard tube spacer 30 e, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

As the aerosol passes through the flavored terminal filter element 26 e, some of the aerosol picks up menthol flavorant as it passes through the cellulose acetate tow. The remainder of the aerosol passes through the axial bore of the terminal filter element 26 e so that it remains substantially unflavored. This provides the user with an aerosol for inhalation that comprises a mix of flavored and unflavored aerosol that provides milder flavor than some other known consumables.

Seventh Mode: A Consumable Providing Two Different Aerosol-Forming Materials

As shown in FIG. 27, the HNB consumable 10 f comprises an aerosol-forming substrate 14 f at the upstream end of the consumable 10 f.

The aerosol-forming substrate 14 f comprises a matrix of reconstituted tobacco 112 throughout which discrete regions 116 of extruded tobacco are interspersed. The extruded tobacco is in the form of macroscopic granules/chips/pellets 120.

The extruded tobacco granules/chips/pellets 120 are evenly spaced and entirely embedded within the matrix of reconstituted tobacco 112.

The aerosol-forming substrate 14 f is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 f is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 f is circumscribed by a paper wrapping layer 18 f.

The consumable 10 f comprises an upstream filter element 22 f and a downstream (terminal) filter element 26 f. The two filter elements 22 f, 26 f and spaced by a cardboard spacer tube 30 f. Both filter elements 22 f, 26 f are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 f, 26 f have a substantially cylindrical shape. The diameter of the upstream filter 22 f matches the diameter of the aerosol-forming substrate 14 f. The diameter of the terminal filter element 26 f is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 f and the wrapping layer 18 f. The upstream filter element 22 f is slightly shorter in axial length than the terminal filter element 26 f at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 f.

The cardboard tube spacer is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 22 f, 26 f is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 22 f is slightly larger than the diameter of the bore in the terminal filter 26 f having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 f.

The cardboard spacer tube 30 f and the upstream filter portion 22 f are circumscribed by the wrapping layer 18 f.

The terminal filter element 26 f is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 f. The tipping layer 42 f encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 f.

FIG. 28 shows a second embodiment of a consumable 10 f′ which is the same as that shown in FIG. 27 except that the terminal filter element 26 f comprises a crushable capsule 34 f (crush-ball 34 f) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 f is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter portion 26 f.

FIG. 29 shows a third embodiment of a consumable 10 f″ which is the same as the first embodiment except that the wrapping layer 18 f does not completely circumscribe the cardboard spacer tube 30 f such that there is an annular gap 50 f between the tipping layer 42 f and the cardboard spacer tube 30 f downstream of the end of the wrapping layer 18 f.

FIG. 30 shows the first embodiment inserted into an HNB device 54 f comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 58 f within the main body 62 f of the device 54 f.

The consumable 10 f is inserted into the cavity 58 f of the main body 62 f of the device 54 f such that the heating rod penetrates the aerosol-forming substrate 14 f. Heating of the reconstituted tobacco 112 in the aerosol-forming substrate 14 f is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 26 f.

As the vapor cools within the upstream filter element 22 f and the cardboard spacer tube 30 f, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Eighth Mode: A Package for Aerosol-Forming Articles

As shown in FIG. 31, the package 140 comprises a packaging 144 containing a plurality of aerosol-forming articles in the form of HNB consumables 10 g.

The packaging 144 comprises a base 152 and an opposing lid 156, spaced by four (side) walls 160 that define a cavity 164 containing the consumables 10 g. The walls 160, lid 156 and base 152 define a generally cuboid or box form, such that the cavity 164 has a rectangular profile. The lid 156 is hingable between a closed position, in which it encloses the consumables 10 g within the cavity 164, and an open position (as is shown in the FIG. 31).

The packaging 144 further comprises an internal liner 168 that lines the four walls 160 and the base 152. As is apparent from the figure, a portion of the liner 168 extends beyond the walls 160 of the packaging 144 when the lid 156 is in the open position. The internal liner 168 comprises a foil that has a flavorant applied as a coating (on an internal surface of the internal liner 168). In the present embodiment the flavorant comprises a menthol flavoring.

The packaging 144 further comprises two pads 172 that are mounted (by way of an adhesive) to an internal surface of the lid 156 of the packaging 144. Each pad 172 is rectangular and is impregnated with a flavorant, which is also in the form of a menthol flavoring. The pads 172 are arranged such that when the lid 156 is in the closed position, they are in contact with ends of the consumables 10 g.

The consumables 10 g are elongate and aligned side-by-side in the cavity 164 such that their longitudinal axes are generally parallel. Although the consumables will be described in further detail below, each consumable comprises an outer wrapper 176 that comprises a flavorant. In this case, the flavorant is sprayed onto the outer wrapper and is in the form of a menthol flavoring.

FIG. 32 shows a second embodiment of the package 140′ that is similar to the first embodiment, except that the internal liner 168 lines the base 152, lid 156 and walls 160 so as to completely enclose the consumables 10 g. Although not shown, the liner 168 comprises a flap that can be opened so as to provide access to the consumables 10 g. In this embodiment, the packaging 144 comprises a single pad 172 that is releasably mounted to an internal surface of the liner 168 that lines the lid 156 (i.e., such that the pad 172 is also enclosed by the liner 168). Unlike the previous embodiment, the pad 172 is spaced from the consumables 10 g, thus the consumables 10 g acquire the flavoring from the pad 172 by way of release of the flavorant into the air in the vicinity of the ends of the consumables 10 g.

FIG. 33 shows a third embodiment of the package 140″ that is similar to the previously described embodiments, except that the liner 168 lines the lid 156 and walls 160 (but not the base 152). Further, this embodiment comprises two pads 172 (only one is apparent from the figure) extending transversely across the base 152 of the packaging 144 such that each pad 172 is aligned with a respective row of consumables 10 g. In the present embodiment, the pads 172 are in contact with the ends of the consumables 10 g. Thus, the consumables 10 g may acquire the flavor of the pads 172 by transfer of the flavorant from the pads 172 to the ends (e.g., comprising the filter or substrate) of the consumables 10 g. In the present case, the flavorant is vanilla, which is different to the menthol flavorant of the internal liner 168.

FIG. 34 shows an exemplary HNB consumable 10 g that may be contained in the packaging described above. The consumable 10 g comprises an aerosol-forming substrate 14 g at the upstream end of the consumable 10 g.

The aerosol-forming substrate 14 g comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 14 g comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 g is formed in a substantially cylindrical shape such that the consumable 10 g resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 g is circumscribed by a paper wrapping layer 18 g. The paper wrapping layer 18 g comprises a (cherry) flavorant applied as a coating to the wrapping layer 18 g.

The consumable 10 g comprises an upstream filter element 22 g and a downstream (terminal) filter element 26 g. The two filter elements 22 g, 26 g are spaced by a cardboard tube spacer 30 g. Both filter elements 22 g, 26 g are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 g, 26 g have a substantially cylindrical shape. The diameter of the upstream filter element 22 g matches the diameter of the aerosol-forming substrate 14 g. The diameter of the terminal filter element 26 g is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 g and the wrapping layer 18 g. The upstream filter element 22 g is slightly shorter in axial length than the terminal filter element 26 g at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 g.

The cardboard tube spacer 30 g is longer than each of the two filter elements 22 g, 26 g having an axial length of around 14 mm.

Each filter element 22 g, 26 g is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 22 g is slightly larger than the diameter of the bore in the terminal filter 26 g having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 g.

The cardboard tube spacer 30 g and the upstream filter element 22 g are circumscribed by the wrapping layer 18 g.

The terminal filter element 26 g is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 g. The tipping layer 42 g encircles the terminal filter element 26 g and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 g. Like the wrapping layer 18 g, the tipping layer 42 g comprises a cherry flavorant. However, the tipping layer 42 g is impregnated (rather than coated) with the flavorant.

FIG. 35 shows a second embodiment of a consumable 10 g′ which is the same as that shown in FIG. 34 except that the terminal filter element 26 g is a solid filter element and comprises a crushable capsule 34 g (crush-ball 34 g) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 g is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter 26 g.

Ninth Mode: A Consumable Providing an Additive Carrier Downstream of an Aerosol-Forming Substrate

As shown in FIG. 36, the HNB consumable 10 h comprises an aerosol-forming substrate 14 h at the upstream end of the consumable 10 h with a cavity 180 immediately adjacent and axially downstream of the aerosol-forming substrate 14 h.

The aerosol-forming substrate 14 h comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 h is formed in a substantially cylindrical shape such that the consumable 10 h resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm. The cavity 180 has an axial length of around 4 mm.

The aerosol-forming substrate 14 h and cavity 180 are circumscribed by a paper wrapping layer 18 h.

The cavity 180 houses a crush ball 188 (i.e., a spherical capsule with a solid, crushable outer wall) containing vegetable glycerin. The crush ball 188 has a diameter of around 3.5 mm and is held within the cavity 180 in abutment with a downstream end 184 of the aerosol-forming substrate 14 h.

The consumable 10 h comprises an upstream filter element 22 h and a downstream (terminal) filter element 26 h. The two filter elements 22 h, 26 h and spaced by a cardboard spacer tube 30 h. Both filter elements 22 h, 26 h are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 h, 26 h have a substantially cylindrical shape. The diameter of the upstream filter 22 h matches the diameter of the aerosol-forming substrate 14 h. The diameter of the terminal filter element 26 h is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 h and the wrapping layer 18 h. The upstream filter element 22 h is slightly shorter in axial length than the terminal filter element 26 h at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 h.

The cardboard tube spacer 30 h is longer than each of the two filter portions having an axial length of around 14 mm.

The terminal filter element 26 h is a hollow bore filter element with a hollow, longitudinally extending bore having a diameter of 2 mm.

The cardboard spacer tube 30 h and the upstream filter element 22 h are circumscribed by the wrapping layer 18 h.

The terminal filter element 26 h is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 h. The tipping layer 42 h encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 h.

FIG. 37 shows a second embodiment of a consumable 10 h′ which is the same as that shown in FIG. 36 except that there is no cavity and the crush ball 188 is held in abutment with the aerosol-forming substrate 14 h embedded within and at the upstream axial end of the upstream filter element 22 h. Furthermore, the terminal filter element 26 h comprises a further crushable capsule 34 h (crush-ball 34 h) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 h is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter portion 26 h. The capsule 34 h may be omitted from the FIG. 37 embodiment and may be included in the FIG. 36 embodiment.

FIG. 38 shows a third embodiment of a consumable 10 h″ which is the same as the first embodiment except that the wrapping layer 18 h does not completely circumscribe the cardboard spacer tube 30 h such that there is an annular gap 50 h between the tipping layer 42 h and the cardboard spacer tube 30 h downstream of the end of the wrapping layer 18 h.

FIG. 39 shows the first embodiment inserted into an HNB device 54 h comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 58 h within the main body 62 h of the device 54 h.

The consumable 10 h is inserted into the cavity 58 h of the main body 62 h of the device 54 h such that the heating rod penetrates the aerosol-forming substrate 14 h. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 h is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 26 h. The crush ball 188 containing VG can be ruptured by pressure to allow the VG to wick into the aerosol-forming substrate to modify the amount of visible vapor during smoking of the consumable.

As the vapor cools within the upstream filter element 22 h and the cardboard spacer tube 30 h, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Tenth Mode: A Consumable Providing Liquid-Containing Capsule that can be Ruptured Mechanically by a Heater Element

As shown in FIG. 40, the HNB consumable 10 i comprises an aerosol-forming substrate 14 i at the upstream end of the consumable 10 i.

The aerosol-forming substrate 14 i comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry/paper recon tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 i is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 i is circumscribed by a paper wrapping layer 18 i.

A crush ball 188 i (i.e., a spherical capsule with a solid, crushable outer wall) containing vegetable glycerin is embedded within the aerosol-forming substrate 14 i. The crush ball has a diameter of around 3.5 mm and is axially spaced from the upstream end 192 of the aerosol-forming substrate 14 i by a distance of less than 12 mm, e.g., between 5-10 mm such as around 7 mm.

The consumable 10 i comprises an upstream filter element 22 i and a downstream (terminal) filter element 26 i. The two filter elements 22 i, 26 i and spaced by a cardboard spacer tube 30 i. Both filter elements 22 i, 26 i are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 i, 26 i have a substantially cylindrical shape. The diameter of the upstream filter 22 i matches the diameter of the aerosol-forming substrate 14 i. The diameter of the terminal filter element 26 i is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 i and the wrapping layer 18 i. The upstream filter element 22 i is slightly shorter in axial length than the terminal filter element 26 i at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 i.

The cardboard tube spacer 30 i is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 22 i, 26 i is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter is slightly larger than the diameter of the bore in the terminal filter having a diameter of 3 mm compared to 2 mm for the terminal filter element.

The cardboard spacer tube 30 i and the upstream filter portion 4 are circumscribed by the wrapping layer 18 i.

The terminal filter element 26 i is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 i. The tipping layer 42 i encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 i.

FIG. 41 shows a second embodiment of a consumable 10 i′ which is the same as that shown in FIG. 40 except that the terminal filter element 26 i comprises a further crushable capsule 34 i (crush-ball 34 i) having a shell containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 i is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter portion 26 i.

FIG. 42 shows a third embodiment of a consumable 10 i″ which is the same as the first embodiment except that the wrapping layer 18 i does not completely circumscribe the cardboard spacer tube 30 i such that there is an annular gap 50 i between the tipping layer 42 i and the cardboard spacer tube 30 i downstream of the end of the wrapping layer 18 i.

FIG. 43 shows the first embodiment inserted into an HNB device 54 i comprising a rod-shaped heating element 90 i. The heating element 16 projects into a cavity 58 i within the main body 62 i of the device by a distance of around 12 mm.

The consumable 10 i is inserted into the cavity 58 i of the main body 62 i of the device 54 i such that the heating rod 90 i penetrates the aerosol-forming substrate 14 i from the upstream axial end 192. Given that the axial spacing of the crush ball 188 i from the upstream axial end 192 of the aerosol-forming substrate 14 i is less than the length of the heating element 90 i/less than the length that the heating element projects into the cavity, as the heating element 16 penetrates the aerosol-forming substrate, the heating element mechanically ruptures the crush ball 188 i so that the VG is released into the tobacco of the aerosol-forming substrate 14 i.

Heating of the reconstituted tobacco in the aerosol-forming substrate 14 i is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the VG released from the ruptured liquid pod are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 26 i. The VG released from the crush ball 188 i increases the amount of visible vapor during smoking of the consumable.

As the vapor cools within the upstream filter element 22 i and the cardboard spacer tube 30 i, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

Eleventh Mode: A Consumable Providing an Increased Concentration of Volatile Compound

As shown in FIG. 44, the HNB consumable 10 k comprises an aerosol-forming substrate 14 k at the upstream end of the consumable 10 k.

The aerosol-forming substrate 14 k comprises reconstituted tobacco which includes nicotine as a volatile compound and which is dosed with up to 20 wt % of a flavorant coating, where the flavorant is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavor, vanilla, spice, coffee, Eucalyptus, and tobacco flavor.

The aerosol-forming substrate 14 k comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry-type reconstituted tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 k is formed in a substantially cylindrical shape such that the consumable 10 k resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 k is circumscribed by a paper wrapping layer 18 k.

The consumable 10 k comprises an upstream filter element 22 k and a downstream (terminal) filter element 26 k. The two filter elements 22 k, 26 k and spaced by a cardboard tube spacer 6. Both filter elements 22 k, 26 k are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 k, 26 k have a substantially cylindrical shape. The diameter of the upstream filter 22 k matches the diameter of the aerosol-forming substrate 14 k. The diameter of the terminal filter element 26 k is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 k and the wrapping layer 18 k. The upstream filter element 22 k is slightly shorter in axial length than the terminal filter element 26 k at an axial length of 10 mm compared to 12 mm for the terminal filer element 26 k.

The cardboard tube spacer 30 k is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 22 k, 26 k is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter 22 k is slightly larger than the diameter of the bore in the terminal filter 26 k having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 k.

The cardboard tube spacer 30 k and the upstream filter portion 22 k are circumscribed by the wrapping layer 18 k.

The terminal filter element 26 k is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 k. The tipping layer 42 k encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 k.

FIG. 45 shows a second embodiment of a consumable 10 k′ which is the same as that shown in FIG. 44 except that the terminal filter element 26 k comprises a crushable capsule 34 k (crush-ball 34 k) containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 k is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter portion 26 k.

FIG. 46 shows a third embodiment of a consumable 10 k″ which is the same as the first embodiment except that the wrapping layer 18 k does not completely circumscribe the cardboard tube spacer 30 k such that there is an annular gap 50 k between the tipping layer 42 k and the cardboard tube spacer 30 k downstream of the end of the wrapping layer 18 k.

FIG. 47 shows the first embodiment inserted into an HNB device 54 k comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 58 k within the main body 62 k of the device 54 k.

The consumable 10 k is inserted into the cavity 58 k of the main body 62 k of the device 54 k such that the heating rod penetrates the aerosol-forming substrate 14 k. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 k is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the aerosol former are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 26 k.

As the vapor cools within the upstream filer element 22 k and the cardboard tube spacer 30 k, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

FIG. 48 shows an illustrative diagram of an embodiment of the manufacturing process 200. Tobacco is ground to reduce the particle size to less than 120 microns (step 204).

The ground tobacco step 204 is then combined with a guar gum binder, cellulose pulp filler, propylene glycol and vegetable glycerin to form a mixture in step 208.

The mixture from step 208 is combined with an aqueous medium to form a slurry in step 212. Mixing of the mixture from step 208 with the aqueous medium is carried out in a high shear mixer. The tobacco content of the slurry is approximately 50 to 90% of the total solids content of the slurry, where the total solids content is 15 to 30 weight % of the slurry.

The resultant slurry from step 212 is cast onto a dryer belt to form a sheet in step 216. The sheet from step 216 is dried using a steam drying apparatus to remove excess moisture content from the sheet until the sheet is self-supporting in step 220.

After step 220, the sheet is wound onto a bobbin for storage in step 224. The moisture content of the cast sheet at winding is about 7 to 15 percent of dry weight of the tobacco sheet. After step 224, a flavorant is applied to the sheet using spray-coating to provide a flavorant coating on the sheet at step 228.

After step 228, the sheet can subsequently be made into a whole or part of an HNB consumable suitable for an HNB device in step 232. Step 232 is achieved by cutting the sheet to an appropriate size. After step 232, the sheet may be used as whole or part of an HNB consumable for an HNB device in step 236. In particular, it is a slurry-type reconstituted tobacco product for use in an HNB device.

In an alternative embodiment the flavorant is applied (step 228) to the dry sheet after step 220 and before winding onto a bobbin for storage (step 224).

Twelfth Mode: A Consumable Providing Aerosol-Forming Substrate Having an Increased Concentration of Volatile Compound

As shown in FIG. 49, the HNB consumable 10 m comprises an aerosol-forming substrate 14 m at the upstream end of the consumable 10 m.

The aerosol-forming substrate 14 m comprises reconstituted tobacco which includes nicotine as a volatile compound and which is dosed with up to 20 wt % of flavorant selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavor, vanilla, spice, coffee, Eucalyptus, and tobacco flavor.

The aerosol-forming substrate 14 m comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 m is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 m is circumscribed by a paper wrapping layer 18 m.

The consumable 10 m comprises an upstream filter element 22 m and a downstream (terminal) filter element 26 m. The two filter elements 22 m, 26 m and spaced by a cardboard tube spacer 30 m. Both filter elements 22 m, 26 m are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 m, 26 m have a substantially cylindrical shape. The diameter of the upstream filter element 22 m matches the diameter of the aerosol-forming substrate 14 m. The diameter of the terminal filter element 26 m is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 m and the wrapping layer 18 m. The upstream filter element 22 m is slightly shorter in axial length than the terminal filter element 26 m at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 m.

The cardboard tube spacer 30 m is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 22 m, 26 m is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 22 m is slightly larger than the diameter of the bore in the terminal filter element 26 m having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 m.

The cardboard tube spacer 30 m and the upstream filter portion 22 m are circumscribed by the wrapping layer 18 m.

The terminal filter element 26 m is joined to the upstream elements forming the consumable 10 m by a circumscribing paper tipping layer 42 m. The tipping layer 42 m encircles the terminal filter portion and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 m.

FIG. 50 shows a second embodiment of a consumable 10 m′ which is the same as that shown in FIG. 49 except that the terminal filter element 26 m comprises a crushable capsule 34 m (crush-ball 34 m) containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 m is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter portion 26 m.

FIG. 51 shows a third embodiment of a consumable 10 m″ which is the same as the first embodiment except that the wrapping layer 18 m does not completely circumscribe the cardboard tube spacer 30 m such that there is an annular gap 50 m between the tipping layer 42 m and the cardboard tube spacer 30 m downstream of the end of the wrapping layer 18 m.

FIG. 52 shows the first embodiment inserted into an HNB device 54 m comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 58 m within the main body 62 m of the device.

The consumable 10 m is inserted into the cavity 58 m of the main body 62 m of the device 54 m such that the heating rod penetrates the aerosol-forming substrate 14 m. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 m is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the aerosol former are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 26 m.

As the vapor cools within the upstream filer element 22 m and the cardboard tube spacer 30 m, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

FIG. 53 shows an illustrative diagram of an embodiment of the manufacturing method 200 m. Tobacco is ground to reduce the particle size to less than 120 microns in step 204 m.

The ground tobacco from step 204 m is then combined with a guar gum binder, cellulose pulp filler, propylene glycol and vegetable glycerin to form a mixture in step 208 m.

The mixture from step 208 m is combined with an aqueous medium to form a slurry in step 212 m. Mixing of the mixture in step 212 m with the aqueous medium is carried out in a high shear mixer. The tobacco content of the slurry is approximately 50 to 90% of the total solids content of the slurry, where the total solids content is 15 to 30 weight % of the slurry.

A flavorant contained within a propylene glycol or vegetable glycerin base liquid, where the flavorant content is within the range 1 to 50 weight % of total weight of flavorant and base liquid, is combined with the slurry in step 214 m.

The resultant slurry of step 214 m is cast onto a dryer belt to form a sheet in step 216 m. The sheet is then dried using a steam drying apparatus to remove excess moisture content from the sheet until the sheet is self-supporting in step 220 m.

The sheet from step 220 m is wound onto a bobbin for storage in step 224 m. The moisture content of the cast sheet at winding is about 7 to 15 percent of dry weight of the tobacco sheet.

The sheet from step 224 m can subsequently be made into a whole or part of an HNB consumable suitable for an HNB device in step 232 m. This is achieved by cutting the sheet to an appropriate size. The sheet may be used as whole or part of an HNB consumable for an HNB device of step 232 m. In particular, it is a slurry-type reconstituted tobacco product for use in an HNB device 54 m.

Thirteenth Mode: A Consumable Providing an Aerosol-Forming Substrate Having an Increased Concentration of Volatile Compound

As shown in FIG. 54, the HNB consumable 10 n comprises an aerosol-forming substrate 14 n at the upstream end of the consumable 10 n.

The aerosol-forming substrate 14 n comprises reconstituted tobacco which includes nicotine as a volatile compound and which is dosed with up to 20 wt % of a casing component selected from sugars, cocoa, carob bean extract, licorice, and fruit extracts.

The aerosol-forming substrate 14 n comprises 65 wt % tobacco which is provided in the form of gathered shreds produced from a sheet of slurry tobacco. The tobacco is dosed with 20 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and has a moisture content of between 7-9 wt %. The aerosol-forming substrate further comprises cellulose pulp filler and guar gum binder.

The aerosol-forming substrate 14 n is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has diameter of around 7 mm and an axial length of around 12 mm.

The aerosol-forming substrate 14 n is circumscribed by a paper wrapping layer 18 n.

The consumable 10 n comprises an upstream filter element 22 n and a downstream (terminal) filter element 26 n. The two filter elements 22 n, 26 n and spaced by a cardboard tube spacer 30 n. Both filter elements 22 n, 26 n are formed of cellulose acetate tow and wrapped with a respective paper plug layer (not shown).

Both filter elements 22 n, 26 n have a substantially cylindrical shape. The diameter of the upstream filter element 22 n matches the diameter of the aerosol-forming substrate 14 n. The diameter of the terminal filter element 26 n is slightly larger and matches the combined diameter of the aerosol-forming substrate 14 n and the wrapping layer 18 n. The upstream filter element 22 n is slightly shorter in axial length than the terminal filter element 26 n at an axial length of 10 mm compared to 12 mm for the terminal filter element 26 n.

The cardboard tube spacer 30 n is longer than each of the two filter portions having an axial length of around 14 mm.

Each filter element 22 n, 26 n is a hollow bore filter element with a hollow, longitudinally extending bore. The diameter of the bore in the upstream filter element 22 n is slightly larger than the diameter of the bore in the terminal filter element 26 n having a diameter of 3 mm compared to 2 mm for the terminal filter element 26 n.

The cardboard tube spacer 30 n and the upstream filter portion 22 n are circumscribed by the wrapping layer 18 n.

The terminal filter element 26 n is joined to the upstream elements forming the consumable by a circumscribing paper tipping layer 42 n. The tipping layer 42 n encircles the terminal filter portion 26 n and has an axial length of around 20 mm such that it overlays a portion of the cardboard tube spacer 30 n.

FIG. 55 shows a second embodiment of a consumable 10 n′ which is the same as that shown in FIG. 54 except that the terminal filter element 26 n comprises a crushable capsule 34 n (crush-ball 34 n) containing a liquid menthol or cherry or vanilla flavorant. The capsule 34 n is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter portion 26 n.

FIG. 56 shows a third embodiment of a consumable 10 n″ which is the same as the first embodiment except that the wrapping layer 18 n does not completely circumscribe the cardboard tube spacer 30 n such that there is an annular gap 50 n between the tipping layer 42 n and the cardboard tube spacer 30 n downstream of the end of the wrapping layer 18 n.

FIG. 57 shows the first embodiment inserted into an HNB device 54 n comprising a rod-shaped heating element (not shown). The heating element projects into a cavity 58 n within the main body 62 n of the device 54 n.

The consumable 10 n is inserted into the cavity 58 n of the main body 62 n of the device 54 n such that the heating rod penetrates the aerosol-forming substrate 14 n. Heating of the reconstituted tobacco in the aerosol-forming substrate 14 n is effected by powering the heating element (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the aerosol former are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 26 n.

As the vapor cools within the upstream filer element 22 n and the cardboard tube spacer 30 n, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

FIG. 58 shows an illustrative diagram of an embodiment of the manufacturing method 200 n. Tobacco is ground to reduce the particle size to less than 120 microns in step 204 n

The ground tobacco of step 204 n is then combined with a guar gum binder, cellulose pulp filler, propylene glycol and vegetable glycerin to form a mixture in step 208 n.

The mixture from step 208 n is combined with an aqueous medium to form a slurry in step 212 n. Mixing of the mixture of step 212 n with the aqueous medium is carried out in a high shear mixer. The tobacco content of the slurry is approximately 50 to 90% of the total solids content of the slurry, where the total solids content is 15 to 30 weight % of the slurry.

A casing component selected from sugars, cocoa, carob bean extract, licorice, and fruit extracts is combined with the slurry of step 212 n and mixed to homogenize in step 215 n. The amount of casing component is selected so as to ultimately provide a casing component content of up to 20 weight % in the dried tobacco sheet. The resultant slurry of step 215 n is cast onto a dryer belt to form a sheet in step 216 n. The sheet is dried using a steam drying apparatus to remove excess moisture content from the sheet until the sheet is self-supporting in step 220 n.

The sheet is wound onto a bobbin for storage in step 224 n. The moisture content of the cast sheet at winding is about 7 to 15 percent of dry weight of the tobacco sheet.

The sheet can subsequently be made into a whole or part of an HNB consumable suitable for an HNB device 54 n in step 232 n. This is achieved by cutting the sheet to an appropriate size. The sheet may be used as whole or part of an HNB consumable 10 n for an HNB device 54 n. In particular, it is a slurry-type reconstituted tobacco product for use in an HNB device 54 n.

The features disclosed in the foregoing description, or in the following claims, or in the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for obtaining the disclosed results, as appropriate, may, separately, or in any combination of such features, be utilized for realizing the invention in diverse forms thereof.

While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the invention.

For the avoidance of any doubt, any theoretical explanations provided herein are provided for the purposes of improving the understanding of a reader. The inventors do not wish to be bound by any of these theoretical explanations.

Any section headings used herein are for organizational purposes only and are not to be construed as limiting the subject matter described.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

It must be noted that, as used in the specification and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” one particular value, and/or to “about” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by the use of the antecedent “about,” it will be understood that the particular value forms another embodiment. The term “about” in relation to a numerical value is optional and means, for example, +/−10%.

The words “preferred” and “preferably” are used herein refer to embodiments of the invention that may provide certain benefits under some circumstances. It is to be appreciated, however, that other embodiments may also be preferred under the same or different circumstances. The recitation of one or more preferred embodiments therefore does not mean or imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, or from the scope of the claims. 

What is claimed is:
 1. An aerosol-forming article comprising: an aerosol-forming substrate; and a filter element; wherein the filter element is at least partly circumscribed by a flavored sleeve.
 2. An article according to claim 1, wherein the article is a heat not burn (HNB) consumable.
 3. An article according to claim 1 or 2 wherein at least a portion of the flavored sleeve is formed of an absorbent material impregnated with flavorant.
 4. An article according to any one of claims 1-3, wherein filter element further comprises at least one flavor pod.
 5. An article according to any one of claims 1-4, wherein, the filter element is a terminal filter element provided at the downstream axial end of the aerosol-forming article.
 6. An article according to claim 5 wherein the terminal filter element is circumscribed by a tipping layer and the sleeve is interposed between the terminal filter element and the tipping layer.
 7. An article according to any one of claims 1 to 4 wherein the filter element is an upstream filter element, upstream from the downstream axial end of the article and axially adjacent the aerosol-forming substrate.
 8. An article according to claim 7 wherein the upstream filter element is circumscribed by a wrapping layer and the sleeve is interposed between the upstream filter element and the wrapping layer.
 9. An article according to any one of claims 1 to 4 wherein the article comprises a terminal filter element and an upstream filter element wherein the flavored sleeve circumscribes one of the filter elements.
 10. An article according to claim 9 wherein the upstream and terminal filter elements are axially spaced by an aerosol-cooling element and/or a spacer element.
 11. A smoking substitute system comprising an article according to any one of claims 1-10 and a device comprising a heating element.
 12. A system according to claim 11 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 13. A method of using the system according to claim 11 or 12, the method comprising: inserting the article into the device; and heating the article using the heating element.
 14. A method according to claim 13 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 15. A method according to claim 13 or 14 comprising releasing flavorant from the flavor pod before or during heating of the article by rupturing or melting an outer shell of the flavor pod.
 16. An aerosol-forming article comprising an aerosol-forming substrate and at least one filter element downstream of the substrate wherein the article has at least one unimpeded flow path along the outer surface of the filter element and wherein the filter element comprises a flavorant additive.
 17. The article according to claim 16 wherein the article is a heat-not-burn (HNB) consumable.
 18. The article according to claim 16 or 17 wherein the filter element is a solid filter element.
 19. The article of any of 16-18 wherein the filter element has an outer surface comprising a plurality of longitudinally-extending channels.
 20. The article according to any one of claims 16-19 further comprising a sleeve circumscribing the filter element.
 21. The article according to any one of claims 16-20, wherein the filter element comprises a longitudinally-extending thread carrying the flavorant additive.
 22. The article according to any one of claims 16-21, wherein the filter element is a terminal filter element provided at the downstream axial end of the article.
 23. The article/consumable according to claim 22 further comprising an upstream filter element upstream from the terminal filter element.
 24. The article according to claim 23 wherein the upstream filter element is a hollow bore filter element.
 25. The article/consumable according to claim 23 or 24 wherein the terminal filter element and the upstream filter element are axially spaced by an aerosol-cooling element and/or a spacer element.
 26. A system comprising a smoking substitute article according to any one of claims 16-25, and a device comprising a heating element.
 27. A system according to claim 26 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 28. A method of using the system according to claim 26 or 27, the method comprising: inserting the article into the device; and heating the article using the heating element.
 29. A method according to claim 28 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 30. An aerosol-forming article comprising a spacer element adapted to impart flavor to a vapor/aerosol.
 31. An article according to claim 30 comprising: an aerosol-forming substrate and a spacer element downstream of the substrate; wherein the spacer element comprises a flavorant.
 32. An article according to claim 30 wherein the article is a heat not burn consumable.
 33. An article according to any one of claims 30 to 32 further comprising a terminal filter element at an axially downstream end of the article.
 34. An article according to claim 33 wherein the spacer element is provided axially adjacent and upstream of the terminal filter element.
 35. An article according to claim 33 or 34 further comprising an upstream filter element and wherein the spacer element is provided between the terminal filter element and the upstream filter element.
 36. An article according to any one of claims 30-35, wherein the spacer element is a tubular spacer element.
 37. An article according to claim 36 wherein the spacer element comprises a tube formed of cardboard or extruded plastic material.
 38. An article according to any one of claims 30-37, wherein spacer element is impregnated with flavorant or comprises a layer of flavorant on an inside surface.
 39. A system comprising an article according to any one of claims 30-38, and a device comprising a heating element.
 40. A system according to claim 39 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 41. A method of using the system according to claim 39 or 40, the method comprising: inserting the article into the device; and heating the article using the heating element.
 42. A method according to claim 41 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 43. An aerosol-forming article comprising an aerosol-forming substrate and at least one of a downstream filter element, spacer element and aerosol-cooling element, wherein the article is circumscribed by a flavored outer wrapper and wherein at least one of the substrate, the filter element, the spacer element, and the cooling element comprises a flavorant additive.
 44. An article according to claim 43 wherein the article is a heat-not-burn (HNB) consumable.
 45. An article according to claim 43 or 44 wherein the outer wrapper comprises a wrapping layer circumscribing the aerosol-forming substrate.
 46. An article according to claim 45 wherein the wrapping layer further circumscribes one or more of the filter element, aerosol-cooling element and spacer element.
 47. An article according to claim 46 wherein the wrapping layer is flavored on its inner surface at a portion overlying one or more of the substrate, the upstream filter element, cooling element and spacer element.
 48. An article according to any one of claims 45 to 47 wherein the outer wrapper further comprises a tipping layer at its axial downstream end which overlies a portion of the wrapping layer.
 49. An article according to claim 48 wherein at least a portion of the tipping paper is flavored on its outer surface.
 50. An article according to claim 49 wherein the tipping paper circumscribes a terminal filter element.
 51. An article according to claim 50 further comprising an upstream filter element circumscribed by the wrapping layer.
 52. An article according to claim 51 wherein the terminal and upstream filter elements are axially spaced by the cooling element and/or the spacer element.
 53. An article according to any one of claims 43-52, wherein the spacer element comprises a tubular element having the flavorant additive coated/sprayed on its inside surface or being impregnated with the flavorant additive.
 54. An article according to anyone of claims 43-53 wherein the cooling element comprises a flavorant additive.
 55. An article according to any one of claims 50 to 54 wherein the filter element, upstream filter element and/or terminal filter element comprises a frangible capsule containing the flavorant additive and/or a flavored additive-soaked thread.
 56. A system comprising a smoking substitute article according to any one of claims 43-55, and a device comprising a heating element.
 57. A system according to claim 56 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 58. A method of using the system according to claim 56 or 57, the method comprising: inserting the article into the device; and heating the article using the heating element.
 59. A method according to claim 56 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 60. An aerosol-forming article comprising an aerosol-forming substrate and a layer of non-combustible material comprising a flavorant, wherein the layer of non-combustible material encloses at least a portion of the aerosol-forming substrate.
 61. An aerosol-forming article according to claim 60, comprising: a wrapping layer with a laminate structure comprising a first layer and a second layer, the first layer being an inner layer adjacent the aerosol-forming substrate and the second layer lying outside the first layer; wherein the first layer comprises the non-combustible material.
 62. An aerosol-forming article according to claim 61 wherein the second layer consists of cellulosic material.
 63. An aerosol-forming article according to claim 62 wherein the cellulosic material comprises paper.
 64. An aerosol-forming article according to any one of claims 60 to 63 wherein the non-combustible material comprises a metallic foil.
 65. An aerosol-forming article according to claim 64 wherein the metallic foil is aluminum foil.
 66. An aerosol-forming article according to any one of claims 60 to 65, wherein an inner surface of the layer of non-combustible material adjacent to the aerosol-forming substrate carries the flavorant.
 67. An aerosol-forming article according to any one of claims 60 to 66, wherein the flavorant is applied to a surface of the layer of non-combustible material by spraying.
 68. An aerosol-forming article according to any one of claims 60 to 67, wherein the flavorant comprises menthol.
 69. An aerosol-forming article according to any one of claims 60 to 68, wherein the aerosol-forming substrate comprises a cylindrical rod of plant material.
 70. An aerosol-forming article according to claim 69, wherein the layer of non-combustible material circumscribes the axially extending curved surface of the cylindrical rod of plant material.
 71. An aerosol-forming article according to any one of claims 60 to 70 wherein the aerosol-forming article is a heat-not-burn consumable.
 72. A system comprising an aerosol-forming article according to any one of the preceding claims and a device comprising a heating element.
 73. A system according to claim 72 wherein the device comprises: a main body for housing the heating element; and the heating element comprises an elongated heating element.
 74. A method of using the system according to claim 72 or 73, the method comprising: inserting the aerosol-forming article into the device; and heating the aerosol-forming article using the heating element.
 75. A method according to claim 74 comprising inserting the aerosol-forming article into a cavity within a main body of the device main body and penetrating the aerosol-forming article with the heating element upon insertion of the aerosol-forming article.
 76. An aerosol-forming article comprising an aerosol-forming substrate and at least one hollow bore filter element downstream from the aerosol-forming substrate wherein the at least one hollow bore filter element comprises a flavorant additive.
 77. The article according to claim 76 wherein the article is a heat-not-burn (HNB) consumable.
 78. The article according to claim 76 or claim 77 comprising a terminal hollow bore filter element at the downstream axial end of the article and/or an upstream hollow bore filter element upstream from the downstream axial end of the article comprising the flavorant additive.
 79. The article according to claim 78 comprising a terminal hollow bore filter element with the flavorant additive and further comprising an upstream filter element.
 80. The article according to claim 79 wherein the upstream filter element is a hollow bore filter element.
 81. The article according to claim 78 comprising an upstream hollow bore filter element with the flavorant additive and further comprising a terminal filter element.
 82. The article according to claim 81 wherein the terminal filter element is a hollow bore filter element.
 83. The article according to any one of claims 78 to 82 wherein the terminal filter and element upstream filter elements are axially spaced by a spacer element and/or a cooling element.
 84. The article according to any one of claims 76-83, wherein the or each hollow bore filter comprises cellulose acetate tow, activated charcoal, paper, or polymer tow.
 85. The article according to any one of claims 76-84, wherein the or each hollow bore filter element has a bore diameter of between 2 and 4 mm.
 86. The article according to any one of claims 76-85, wherein the flavorant additive is evenly dispersed throughout the hollow bore filter element.
 87. A system, comprising: a smoking substitute article according to any one of the preceding claims; and a device comprising a heating element.
 88. A system according to claim 87 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 89. A method of using the system according to claim 87 or 88, the method comprising: inserting the article into the device; and heating the article using the heating element.
 90. A method according to claim 89 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 91. An aerosol-forming article comprising an aerosol-forming substrate wherein the aerosol-forming substrate comprises at least one discrete region of a first aerosol-forming material within a matrix of a second aerosol-forming material.
 92. An article according to claim 91 comprising a plurality of discrete regions of the first aerosol-forming material dispersed within the matrix of the second aerosol-forming material.
 93. An article according to claim 92 wherein the plurality of discrete regions of first aerosol-forming material is evenly spaced within the matrix of the second aerosol-forming material.
 94. An article according to claim 92 or 93 wherein the plurality of discrete regions of first aerosol-forming material are entirely embedded within the matrix of the second aerosol-forming material.
 95. An article according to any one of claims 91-94, wherein the first and/or second aerosol-forming material each comprise plant material.
 96. An article according to claim 95 wherein the first aerosol-forming material and the second aerosol-forming material each comprises tobacco.
 97. An article according to claim 96 wherein the second aerosol-forming material comprises one or more of tobacco, tobacco derivatives, expanded tobacco, shredded tobacco and/or reconstituted tobacco.
 98. A smoking substitute article according to claim 96 or 97 wherein the first aerosol-forming material comprises extruded tobacco.
 99. An article according to claim 98 wherein the second aerosol-forming material comprises reconstituted tobacco and the first aerosol-forming material comprises extruded tobacco.
 100. An article according to claim 98 or 99 wherein the first aerosol-forming material comprises pellet, granules or chips of extruded tobacco.
 101. An article according to any one of claims 91-100, wherein the aerosol-forming substrate comprises one or more additives selected from humectants, flavorants and/or binders.
 102. A smoking substitute system comprising an article according to any one of claims 91-101, and a device comprising a heating element.
 103. A system according to claim 102 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 104. A method of using the system according to claim 102 or 103, the method comprising: inserting the article into the device; and heating the article using the heating element.
 105. A method according to claim 104 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 106. A packaging for a plurality of aerosol-forming articles, the packaging comprising: a base and an opposing lid spaced by one or more walls so as to define a cavity for the aerosol-forming articles; and an internal liner, the liner lining at least a portion of the one or more walls, wherein the packaging comprises a first flavorant source provided on the liner and a second flavorant source provided on pad disposed on an internal surface of the packaging.
 107. Packaging according to claim 106 wherein the internal liner lines the base, lid and one or more walls so as to enclose the aerosol-forming articles when received therein.
 108. Packaging according to claim 106 or 107 wherein the pad is disposed on an internal surface of the lid or the base.
 109. Packaging according to claim 107 wherein the pad is disposed on an internal surface of the liner.
 110. Packaging according to claim 109 wherein the pad is disposed on an internal surface of the liner that lines the lid or base.
 111. Packaging according to any one of claims 106-110, wherein the flavorant is coated, sprayed or painted onto the internal liner and/or the pad.
 112. Packaging according to any one of claims 106-111 wherein both the first and second flavorant sources comprise menthol.
 113. An aerosol-forming article package comprising: a base and an opposing lid spaced by one or more walls so as to define a cavity containing a plurality of aerosol-forming articles, each article comprising an outer wrapping layer comprising a flavorant; an internal liner comprising a flavorant and lining at least a portion of the one or more walls.
 114. A package according to claim 113 wherein each aerosol-forming article comprises an aerosol-forming substrate and a terminal filter element downstream of the aerosol-forming substrate.
 115. A package according to claim 114 wherein the outer wrapper of each aerosol-forming article comprises a wrapping layer at least partly circumscribing the aerosol-forming substrate, the wrapping layer comprising the flavorant.
 116. A package according to claim 114 or 115 wherein the outer wrapper of each aerosol-forming article comprises a tipping layer at least partly circumscribing the terminal filter of the aerosol-forming article, the tipping layer comprising the flavorant.
 117. A package according to claim 116 wherein the flavorant is applied to an outer surface of the tipping layer of each aerosol-forming article.
 118. A package according to any one of claims 113 to 117 wherein the flavorant is coated, sprayed or painted onto the outer wrapper of each aerosol-forming article.
 119. A package according to any one claim 113 to 118 wherein each aerosol-forming article is a heat-not-burn (HNB) consumable.
 120. A method of flavoring an aerosol-forming article, the method comprising: providing a packaging according to any one of claims 106 to 112; and sealing an unflavored aerosol-forming article within the packaging for a period of time such that the aerosol-forming article acquires the flavor of the first and/or second flavorant source.
 121. An aerosol-forming article comprising an aerosol-forming substrate wherein the article further comprises an additive carrier downstream and adjacent the aerosol-forming substrate.
 122. An article according to claim 121 wherein the additive carrier is housed in a cavity which is downstream and axially adjacent the aerosol-forming substrate.
 123. An article according to claim 122 wherein the cavity is dimensioned such that the additive carrier is held in abutment/contact with the downstream end of the aerosol-substrate.
 124. An article according to claim 121 wherein the additive carrier is embedded in an upstream end of a filter element axially adjacent the aerosol-forming substrate.
 125. An article according to any one of claims 121-124, wherein the additive carrier a crushable or meltable capsule or micro-molding.
 126. An article according to any one of claims 121-125, wherein the additive carrier carries a liquid additive.
 127. An article according to any one of claims 121-126, wherein the additive carrier carries an additive selected from humectants or flavorants.
 128. An article according to any one of claims 121-127, wherein the additive carrier carries one or more of propylene glycol (PG), triethylene glycol, 1, 2-butane diol, vegetable glycerin (VG) and their esters.
 129. An article according to any one of claims 121-128, wherein the aerosol-forming substrate comprises tobacco.
 130. A smoking substitute system comprising an article according to any one of claims 121-129, and a device comprising a heating element.
 131. A system according to claim 129 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 132. A method of using the system according to claim 130 or 131, the method comprising: inserting the article into the device; and heating the article using the heating element.
 133. A method according to claim 132 comprising inserting the article into a cavity within a main body of the device and penetrating the article with the heating element upon insertion of the article.
 134. A method according to claim 132 or 133 comprising releasing additive from the additive carrier during heating of the article by rupturing or melting an outer shell of the additive carrier.
 135. An aerosol-forming article comprising an aerosol-forming substrate wherein the article further comprises a liquid pod enclosed within the aerosol-forming substrate and adapted to be ruptured mechanically upon coupling with a heating element.
 136. An article according to claim 134 wherein the liquid pod comprises one or more humectant and/or flavorant.
 137. An article according to claim 134 or 135 wherein the liquid pod carries one or more of propylene glycol (PG), triethylene glycol, 1, 2-butane diol, vegetable glycerin (VG) and their esters.
 138. An article according to any one of claims 135-137, wherein the liquid pod comprises an outer shell which is mechanically rupturable by the heating element.
 139. An article according to any one of claims 135-138, wherein the liquid pod is axially spaced from the upstream end of the substrate by a distance that is less than the penetration depth of the heating element during coupling with the consumable.
 140. An article according to any one of claims 135-139, wherein the liquid pod is closer to the upstream end of the aerosol-forming substrate than the downstream end.
 141. An article according to any one of claims 135-140, wherein the aerosol-forming substrate comprises tobacco.
 142. A smoking substitute system comprising an article according to any one of claims 135-141, and a device comprising a heating element.
 143. A system according to claim 142 wherein the device comprises a main body for housing the heating element within a cavity and the heating element comprises an elongated heating element which projects into the cavity.
 144. A system according to claim 143 wherein the liquid pod is axially spaced from the upstream end of the aerosol-forming substrate by a distance that is less than the distance that the heating element projects into the cavity.
 145. A method of using the system according to claim 143 or 144, the method comprising: inserting the article into the device such that the heating element penetrates the article and mechanically ruptures the liquid pod; and heating the article using the heating element.
 146. An aerosol-forming article comprising an aerosol-forming substrate dosed with a coating of flavorant, wherein the aerosol-forming substrate is a slurry-type reconstituted plant material, and wherein the flavorant content is up to 20% by weight of the aerosol-forming substrate.
 147. An article according to claim 146, wherein the flavorant is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavor, vanilla, spice, coffee, Eucalyptus, and tobacco flavor.
 148. An article according to any one claim 146 or claim 147 wherein the flavorant is a non-tobacco flavorant
 149. An article according to any one of claims 146-148 wherein the plant material is tobacco.
 150. An article according to any one of claims 146-149 wherein the article is a heat-not-burn (HNB) consumable.
 151. A system comprising a smoking substitute article according to any one of claims 146-150 and a device comprising a heating element.
 152. A system according to claim 151 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 153. A method of using the system according to claim 151 or 152, the method comprising: inserting the article into the device; and heating the article using the heating element.
 154. A method according to claim 153 comprising inserting the article into a cavity within a main body of the device; and penetrating the article with the heating element upon insertion of the article.
 155. A method for manufacturing an aerosol-forming substrate, wherein the aerosol forming substrate is a slurry-type reconstituted plant material, the method comprising: combining a ground plant material with an aqueous medium to form a slurry; casting the slurry on a surface to form a sheet; and applying a flavorant to the sheet to provide a coating.
 156. A method according to claim 155, wherein the flavorant is applied by spray-coating.
 157. A method according to either claim 155 or claim 156, wherein the flavorant is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavor, vanilla, spice, coffee, Eucalyptus, and tobacco flavor.
 158. A method according to any one of claims 155 to 157, wherein the flavorant is a non-tobacco flavor.
 159. A method according to any of claims 155 to 158, wherein the flavorant is synthetically derived menthol.
 160. A method according to any of claims 155 to 159, comprising a step of drying the sheet, wherein the flavorant is applied to the sheet after drying.
 161. A method according to any of claim 155 to 160, comprising a step of winding the sheet onto a bobbin, wherein the flavorant is applied to the sheet after winding.
 162. A method according to any of claims 155 to 161, wherein the plant material is tobacco.
 163. An aerosol-forming substrate for an HNB device produced by a process according to any of claims 155 to
 162. 164. The aerosol-forming substrate according to claim 163, wherein the dosed flavorant content is up to 20% by weight of the aerosol-forming substrate.
 165. A method for manufacturing a heat-not-burn (HNB) consumable comprising an aerosol-forming substrate, wherein the aerosol forming substrate is a slurry-type reconstituted plant material, the method comprising: combining a ground plant material with an aqueous medium to form a slurry; providing a flavorant in the slurry; casting the slurry to form a sheet; drying the sheet to form an aerosol-forming substrate; and incorporating a portion of the aerosol-forming substrate into an HNB consumable.
 166. A method according to claim 165, wherein the flavorant is selected from menthol, peppermint, spearmint, licorice, chocolate, fruit flavor, vanilla, spice, coffee, Eucalyptus, and tobacco flavor.
 167. A method according to claim 166, wherein the flavorant is a non-tobacco flavorant.
 168. A method according to any one of claims 165-167, wherein the flavorant is synthetically derived menthol.
 169. A method according to any one of claims 165-168 wherein the flavorant is provided in an amount resulting in a level of up to 20% by weight of the dried aerosol-forming substrate.
 170. A method according to any one of claims 165-169 wherein the plant material is tobacco.
 171. A method according to any one of claims 165-170 wherein the flavorant is provided in a base liquid.
 172. A method according to claim 171, wherein the base liquid is a polyhydric alcohol.
 173. An HNB consumable formed by a method according to any one of claims 165-172.
 174. A system comprising an HNB consumable according to claim 173 and a device comprising a heating element.
 175. A system according to claim 174 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 176. A method of using the system according to claim 174 or 175, the method comprising: inserting the HNB consumable into the device; and heating the HNB consumable using the heating element.
 177. A method according to claim 176 comprising inserting the HNB consumable into a cavity within a main body of the device and penetrating the HNB consumable with the heating element upon insertion of the HNB consumable.
 178. A method for manufacturing a heat-not-burn (HNB) consumable comprising an aerosol-forming substrate, wherein the aerosol forming substrate is a slurry-type reconstituted plant material, the method comprising: combining a ground plant material with an aqueous medium to form a slurry; providing a casing component in the slurry; casting the slurry to form a sheet; drying the sheet to form an aerosol-forming substrate; and incorporating a portion of the aerosol-forming substrate into an HNB consumable.
 179. A method according to claim 178, wherein the casing component is selected from sugars, non-sugar casings, and combinations thereof.
 180. A method according to claim 178 or 179, wherein the casing component comprises a sugar selected from sucrose, fructose, lactose, glucose, dextrose, mannose, galactose, rhamnose, maltose and xylose, and unrefined sugars selected from maple sugar, cane sugar, molasses, date sugar, honey, agave nectar, and brown rice syrup; and combinations thereof.
 181. A method according to claim 178 or 179, wherein the casing component comprises a non-sugar casing selected from cocoa, carob bean extract, licorice, fruit extracts.
 182. A method according to any of claims 178-181, wherein the casing component is provided in a base liquid.
 183. A method according to claim 182, wherein the base liquid is water and the casing component is provided as an aqueous solution.
 184. A method according to any of claims 178-183, wherein the casing component is provided in an amount suitable to result in an amount of up to 20% by weight of the aerosol-forming substrate.
 185. A method according to any one of claims 178-184 claims wherein the plant material is tobacco.
 186. An HNB consumable produced by a method according to any of claims 178-185.
 187. A system comprising an HNB consumable according to claim 186 and a device comprising a heating element.
 188. A system according to claim 187, wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 189. A method of using the system according to claim 187 or 188, the method comprising: inserting the HNB consumable into the device; and heating the HNB consumable using the heating element.
 190. A method according to claim 189, comprising inserting the HNB consumable into a cavity within a main body of the device and penetrating the HNB consumable with the heating element upon insertion of the HNB consumable. 